Remove
- 1. Remove air intake manifold • Unscrew bolt (2)
- 2. Remove engine vent hose from cylinder head cover • Release clamp (4)
- 3. Detach air intake pipe from air intake hose • Release clamp (1) – Release clamp
- 4. Detach air intake pipe from turbocharger • Release clamp (3)
Note. Seal air intake pipe at turbocharger
- 5. Remove air intake pipe
- 6. Detach engine vent hose (3) from cylinder head cover and engine vent flange
- 7. Detach upper coolant pipe (1) with engine transport shackle from cylinder head
- 8. Lay aside upper coolant pipe
- 9. Remove mounting bolts from heat shield (2)
- 10. Remove heat shield.
- 11. Detach lower nut (3) from wastegate capsule actuator rod
- 12. Remove vacuum line (1) from wastegate capsule (2)
- 13. Undo bolts connecting wastegate capsule to turbocharger and remove wastegate capsule from above
Install
- 14. Screw upper nut of wastegate capsule actuator rod to end of thread
- 15. Insert wastegate capsule actuator rod into wastegate lever free of tension and attach wastegate capsule to turbocharger
- 16. Screw in lower nut of wastegate capsule actuator rod as far as wastegate lever
Note. Screw on nut without pretension until it is lying against wastegate lever
- 17. Adjust pretension • Screw lower nut against spring force for 6 turns • Counterhold upper nut against wastegate lever
Note. If the wastegate capsule is incorrectly prestressed this causes deviations in boost pressure control and leads to error codes being set.
Note. 6 turns with a thread lead of 1 mm on M6 = 6mm depth of thread
- 18. Attach vacuum hose to wastegate capsule
- 19. Install heat shield 9 Nm
- 20. Attach upper coolant pipe with engine transport shackle to cylinder head 20 Nm
- 21. Remove seal from turbocharger air intake pipe
- 22. Attach engine vent hose to cylinder head cover • Fasten clamp
- 23. Attach air intake pipe to turbocharger • Fasten clamp
- 24. Attach air intake pipe to air intake hose • Fasten clamp
- 25. Screw in bolt
- 26. Install engine vent hose