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Removing and installing turbocharger AFN, AVG, AHH, AHU

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The document provides instructions for removing and installing a turbocharger and associated components on different engine codes. It describes ensuring cleanliness and leak-free installations of all hose connections and specifies lubricating the turbocharger before start up. Instructions are provided for specific engine codes AHU, AFN, AVG, and AHH, listing the removal and installation order of components like exhaust manifolds, charge air coolers, oil lines and their associated hardware.

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Charge air system with turbocharger Removing and installing turbocharger with attachments Observe rules for cleanliness => Page 21-2. Notes: â—† All hose connections are secured with clamps and/or securing clips. â—† VAS 5024 A pliers are recommended when installing spring-type clips. â—† Do not install hose connections with lubricant containing oil. â—† Charge air system must be free of leaks. â—† Before screwing on oil supply pipe fill turbocharger at connection with engine oil. â—† After installing turbocharger run engine for approx. 1 minute at idling speed, do not rev engine. This ensures that the turbocharger is adequately lubricated. â—† Renew self-locking nuts. Engine code AHU =>Page 21-4 Engine codes AFN, AVG, AHH =>Page 21-8 Engine code AHU Note: â—† After installing turbocharger run engine for approx. 1 minute at idling, do not rev engine. This ensures that the turbocharger is adequately lubricated. 1. Exhaust manifold 2. 35 Nm â—† Renew â—† Coat threads and bolt head seating surface with G000500 3. Intake manifold
4. From charge air cooler 5. Gasket â—† Renew â—† Coating (beading) towards intake manifold 6. 25 Nm 7. Gasket â—† Note installation position 8. Washer
9. 25 Nm 10. Heat shield 11. To crankcase breather 12. From air cleaner 13. Hose â—† To charge pressure control solenoid valve (N75) => Page 21-20 14. Banjo bolt, 15 Nm 15. Seal â—† Renew 16. 30 Nm 17. Oil return pipe â—† To cylinder block 18. Banjo bolt, 30 Nm 19. Gasket â—† Renew 20. Hose
â—† To charge pressure control solenoid valve (N75) => Page 21-20 21. 10 Nm â—† Install with D6 22. Pressure unit â—† For charge pressure regulating valve â—† Checking =>Page 21-22 â—† Removing and installing => Page 21-23 23. Circlip 24. Turbocharger â—† Checking => Page 21-24 â—† Checking charge pressure control => Page 21-33 25. Gasket â—† Renew 26. Front exhaust pipe
27. Connection, 30 Nm â—† Renew â—† Coat threads and bolt head seating surface with "G 052 112 A3" â—† Before screwing on oil supply pipe fill connection with engine oil 28. Bolt â—† Tightening torque => page 17-8, item 9 29. Oil supply pipe â—† From oil filter bracket => Page 17-3, item 6 â—† Before screwing on oil supply pipe fill connection with engine oil â—† Removing and installing =>page 17-8 Engine codes AFN, AVG, AHH Note:
â—† After installing turbocharger run engine for approx. 1 minute at idling, do not rev engine. This ensures that the turbocharger is adequately lubricated. 1. Exhaust manifold 2. Intake manifold 3. From charge air cooler 4. Gasket â—† Renew â—† Coating (beading) towards intake manifold 5. 25 Nm 6. Gasket â—† Note installation position 7. Retainer
â—† For heat shield item 9 8. Washer 9. Heat shield â—† Engage in bracket item 7 10. Pressure unit â—† For charge pressure control â—† Integral part of turbocharger cannot be replaced 11. Turbocharger â—† Checking charge pressure control => Page 21-33 12. To crankcase breather 13. From air cleaner 14. Gasket â—† Renew 15. 30 Nm 16. Oil return pipe â—† To cylinder block
17. Seal â—† Renew 18. Banjo bolt, 30 Nm 19. Retainer 20. To charge air cooler 21. Gasket â—† Renew 22. Front exhaust pipe 23. Hose â—† To charge pressure control solenoid valve (N75) => Page 21-16 24. Connection, 30 Nm â—† Renew â—† Coat threads and bolt head seating surface with "G 052 112 A3"
â—† Fill connection with engine oil before screwing on oil supply pipe. 25. Bolt â—† Tightening torque => page 17-8, item 9 26. Oil supply pipe â—† From oil filter bracket => Page 17-3, item 6 â—† Fill connection with engine oil before screwing on oil supply pipe. â—† Removing and installing =>page 17-8 27. Retainer 28. 25 Nm â—† Renew â—† Coat threads and bolt head seating surface with G 000 500

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Removing and installing turbocharger AFN, AVG, AHH, AHU

  • 1. Charge air system with turbocharger Removing and installing turbocharger with attachments Observe rules for cleanliness => Page 21-2. Notes: â—† All hose connections are secured with clamps and/or securing clips. â—† VAS 5024 A pliers are recommended when installing spring-type clips. â—† Do not install hose connections with lubricant containing oil. â—† Charge air system must be free of leaks. â—† Before screwing on oil supply pipe fill turbocharger at connection with engine oil. â—† After installing turbocharger run engine for approx. 1 minute at idling speed, do not rev engine. This ensures that the turbocharger is adequately lubricated. â—† Renew self-locking nuts. Engine code AHU =>Page 21-4 Engine codes AFN, AVG, AHH =>Page 21-8 Engine code AHU Note: â—† After installing turbocharger run engine for approx. 1 minute at idling, do not rev engine. This ensures that the turbocharger is adequately lubricated. 1. Exhaust manifold 2. 35 Nm â—† Renew â—† Coat threads and bolt head seating surface with G000500 3. Intake manifold
  • 2. 4. From charge air cooler 5. Gasket â—† Renew â—† Coating (beading) towards intake manifold 6. 25 Nm 7. Gasket â—† Note installation position 8. Washer
  • 3. 9. 25 Nm 10. Heat shield 11. To crankcase breather 12. From air cleaner 13. Hose â—† To charge pressure control solenoid valve (N75) => Page 21-20 14. Banjo bolt, 15 Nm 15. Seal â—† Renew 16. 30 Nm 17. Oil return pipe â—† To cylinder block 18. Banjo bolt, 30 Nm 19. Gasket â—† Renew 20. Hose
  • 4. â—† To charge pressure control solenoid valve (N75) => Page 21-20 21. 10 Nm â—† Install with D6 22. Pressure unit â—† For charge pressure regulating valve â—† Checking =>Page 21-22 â—† Removing and installing => Page 21-23 23. Circlip 24. Turbocharger â—† Checking => Page 21-24 â—† Checking charge pressure control => Page 21-33 25. Gasket â—† Renew 26. Front exhaust pipe
  • 5. 27. Connection, 30 Nm â—† Renew â—† Coat threads and bolt head seating surface with "G 052 112 A3" â—† Before screwing on oil supply pipe fill connection with engine oil 28. Bolt â—† Tightening torque => page 17-8, item 9 29. Oil supply pipe â—† From oil filter bracket => Page 17-3, item 6 â—† Before screwing on oil supply pipe fill connection with engine oil â—† Removing and installing =>page 17-8 Engine codes AFN, AVG, AHH Note:
  • 6. â—† After installing turbocharger run engine for approx. 1 minute at idling, do not rev engine. This ensures that the turbocharger is adequately lubricated. 1. Exhaust manifold 2. Intake manifold 3. From charge air cooler 4. Gasket â—† Renew â—† Coating (beading) towards intake manifold 5. 25 Nm 6. Gasket â—† Note installation position 7. Retainer
  • 7. â—† For heat shield item 9 8. Washer 9. Heat shield â—† Engage in bracket item 7 10. Pressure unit â—† For charge pressure control â—† Integral part of turbocharger cannot be replaced 11. Turbocharger â—† Checking charge pressure control => Page 21-33 12. To crankcase breather 13. From air cleaner 14. Gasket â—† Renew 15. 30 Nm 16. Oil return pipe â—† To cylinder block
  • 8. 17. Seal â—† Renew 18. Banjo bolt, 30 Nm 19. Retainer 20. To charge air cooler 21. Gasket â—† Renew 22. Front exhaust pipe 23. Hose â—† To charge pressure control solenoid valve (N75) => Page 21-16 24. Connection, 30 Nm â—† Renew â—† Coat threads and bolt head seating surface with "G 052 112 A3"
  • 9. â—† Fill connection with engine oil before screwing on oil supply pipe. 25. Bolt â—† Tightening torque => page 17-8, item 9 26. Oil supply pipe â—† From oil filter bracket => Page 17-3, item 6 â—† Fill connection with engine oil before screwing on oil supply pipe. â—† Removing and installing =>page 17-8 27. Retainer 28. 25 Nm â—† Renew â—† Coat threads and bolt head seating surface with G 000 500