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J470400 Turbocharger, Replace (Y 17 DT, with AC, LHD)
1. Open bonnet
2. Drain air conditioning
Note! Drain air conditioning – see operation "Air Conditioning, Drain " in group "D"
Caution!
On vehicles from model year 04 with ESP - the steering angle sensor loses its basic adjustment each time the battery is disconnected. It must be recalibrated.
3. Disconnect battery
Detach ground cable
4. Remove air cleaner housing (1)
Remove wiring harness plug for hot film mass air flow meter (3)
Release in direction of arrow
Remove air intake hose (4)
Loosen clamp (5)
Remove bolt (2)
Object Number: 2411064 Size: DEFAULT
5. Remove oil dipstick guide tube
Unscrew upper bolt
Unclip vacuum hoses
6. Raise vehicle
7. Remove ribbed V-belt cover
Remove 3 bolts (1)
Remove clip (arrow).
Object Number: 2410600 Size: DEFAULT
8. Remove ribbed V-belt
Tension ribbed V-belt tensioner in direction of arrow
Using KM-913-A at fastening bolt (1)
Note! Mark running direction
Object Number: 2415956 Size: DEFAULT
9. Drain engine oil
Place collecting basin underneath.
Unscrew oil drain bolt
10. Remove vacuum pump oil return hose (1)
Release 2 clamps
Object Number: 2411183 Size: DEFAULT
11. Remove oil dipstick guide tube
Remove 2 bolts (arrows)
12. Tighten oil drain bolt (78.4 Nm / 57.8 lbf. ft.)
13. Remove front exhaust pipe
Note: When removing the centre muffler, a catalytic converter, an exhaust manifold, or an exhaust manifold with catalytic converter, secure that portion of the exhaust system remaining on the vehicle against uncontrolled suspension.
For this purpose, the exhaust system portion including the flexpipe may be fastened to the vehicle underbody using suitable means, e.g. wire.
Caution!
Angular dislocations of the flexpipe as small as 5 to 10 degrees offset from the intended installation position can already cause damage and subsequent complete failure of the flexpipe.
Remove 2 nuts
14. Release turbocharger bracket
Remove bolt (1)
Object Number: 2411105 Size: DEFAULT
15. Remove turbocharger oil return hose (2)
Remove 2 clamps
16. Remove turbocharger oil feed line
Unscrew nut (1)
Note! Counterhold at threaded port (2)
Object Number: 2411063 Size: DEFAULT
17. Detach waste gate unit vacuum hose
18. Detach air intake pipe
From turbocharger
Release clamp
19. Detach centre charge air pipe
from lower charge air pipe
Remove lower bolt (1)
Loosen clamp (2)
Object Number: 2411180 Size: DEFAULT
20. Lower vehicle
21. Remove oil dipstick guide tube bracket
Remove 2 nuts (1)
Unclip 2 vacuum hoses
Object Number: 2411179 Size: DEFAULT
22. Remove compressor
Detach refrigerant line
Remove bolt (2)
Disconnect compressor wiring harness plug (3)
Remove 3 bolts (arrows)
Note! Note dissimilar bolt lengths
23. Remove oil dipstick guide tube
24. Remove compressor bracket
Remove 3 bolts
25. Detach centre charge air pipe
Remove upper bolt (1)
Loosen clamp (2)
Remove with charge air hose
Object Number: 2411181 Size: DEFAULT
26. Remove exhaust manifold heat shield
Remove 4 bolts
Object Number: 2411066 Size: DEFAULT
27. Remove wiring harness for engine management
Engine control unit wiring harness plug (1)
Release in direction of arrow
Disconnect combination plug (2) (grey)
Disconnect combination plug (5) (black)
Object Number: 2411182 Size: DEFAULT
28. Remove air intake hose (3)
Remove 2 bolts
Detach engine vent hose (4)
From cylinder head cover
Detach air intake pipe from turbocharger
Unclip wiring harness
29. Remove turbocharger oil feed line
Unscrew banjo bolt (1)
Remove seal rings
Object Number: 2411068 Size: DEFAULT
30. Remove exhaust gas recirculation pipe
Remove 2 bolts (1)
Remove gasket.
Object Number: 2411067 Size: DEFAULT
31. Detach exhaust manifold
Remove 7 bolts
Remove 2 nuts (1)
Remove gasket.
Object Number: 2411069 Size: DEFAULT
32. Remove turbocharger heat shield
Remove 3 bolts
33. Remove turbocharger
Remove 3 nuts
Remove gasket.
Object Number: 2411106 Size: DEFAULT
34. Remove waste gate unit (1)
Remove 2 bolts
Detach retaining clip (arrow)
Object Number: 2411107 Size: DEFAULT
35. Detach oil return port (2)
Remove 2 bolts
Remove gasket.
36. Detach return manifold (1)
Remove 4 nuts
Object Number: 2411108 Size: DEFAULT
37. Clean sealing surfaces
Exhaust manifold, return manifold
38. Attach return manifold
Tighten nuts (26.5 Nm / 19.5 lbf. ft.)
39. Install oil return ports
Replace gasket
Tighten bolts
40. Install waste gate unit
Tighten bolts
Replace retaining clip
41. Install turbocharger
Note: Pour 0.4 ml of clean engine oil into the opening of the oil feed line
Replace gasket
Replace nuts
Tighten nuts (26.5 Nm / 19.5 lbf. ft.)
42. Install turbocharger heat shield
Tighten bolts (11.7 Nm / 8.6 lbf. ft.)
43. Replace oil dipstick guide tube seal
Insert in upper part of oil pan
44. Install exhaust manifold
Replace gasket
Tighten bolts, nuts (23.5 Nm/17.3 lbf. ft.)
45. Attach exhaust gas recirculation pipe
Replace gasket
Tighten bolts (28.4 Nm / 20.9 lbf. ft.)
46. Install turbocharger oil feed line
Renew seal rings
Tighten banjo bolt (20.6 Nm/15.2 lbf. ft.)
47. Attach exhaust manifold heat shield
Tighten bolts (11.7 Nm / 8.6 lbf. ft.)
48. Attach centre charge air pipe
Tighten upper bolt
Fasten clamp
49. Insert oil dipstick guide tube
Replace seal ring
50. Install compressor bracket
Tighten bolts (43 Nm / 31.7 lbf. ft.)
51. Install compressor
Tighten bolts (22 Nm / 16.2 lbf. ft)
Connect wiring harness plug.
Attach refrigerant line
Renew seal rings
Tighten bolt (20 Nm / 15 lbf. ft.)
52. Install oil dipstick guide tube bracket
Tighten nuts
Clip in vacuum hoses
53. Install air intake pipe
Tighten bolts
To turbocharger
Fasten clamp
Attach engine vent hose
Attach wiring harness
54. Attach wiring harness for engine management
Engine control unit wiring harness plug, 2 combination plugs
55. Raise vehicle
56. Attach turbocharger oil feed line
Renew seal rings
Note! Counterhold at threaded port
Tighten nut (9.8 Nm/7.2 lbf. ft.)
57. Install turbocharger oil return line
Fasten clamp
58. Connect waste gate unit vacuum hose
59. Attach turbocharger bracket
Tighten bolt (26.5 Nm / 19.6 lbf. ft.)
60. Install vacuum pump oil return hose
Fasten clamps
61. Fasten centre charge air pipe
Tighten bolt
Fasten clamp (3.5 Nm / 2.6 lbf. ft.)
62. Attach front exhaust pipe
Replace gasket
Replace nuts
Tighten nuts (65 Nm / 48 lbf. ft.)
63. Install oil dipstick guide tube
Tighten lower bolts (9.8 Nm / 7.2 lbf. ft.)
64. Install ribbed V-belt
Note! Observe running direction and installation position
Release ribbed V-belt tensioner
65. Install ribbed V-belt cover
Tighten bolts
Install clip
66. Lower vehicle
67. Fasten oil dipstick guide tube
Tighten upper bolt (9.8 Nm / 7.2 lbf. ft.)
Clip in vacuum hoses
68. Install air cleaner housing
Tighten bolt
Install air intake hose
Fasten clamp (3.5 Nm / 2.6 lbf. ft.)
Attach hot film mass air flow meter wiring harness plug
69. Connect battery
70. Calibrate steering angle sensor
Switch on ignition
Note: Rotate the steering wheel one time from its right-hand to its left-hand stop.
71. Top up engine oil
Observe specified engine oil quantity
Start engine and allow to run until oil pressure telltale extinguishes.
Check engine oil level, if necessary correct.
72. Program volatile memories
73. Charge air conditioning
Note! Charge air conditioning – see operation "Air Conditioning, Evacuate and Charge" in group "D"
74. Close bonnet
