Exhaust system,  OM617

Removal and installation of exhaust gas turbocharger

 

 

09—430 Removal and installation of exhaust gas turbocharger

 

Turbocharger designation

 

Garret
TA 0301

 

Kiihnle Kopp and Kausch KKK 532 679 60 31;

 

x) Start of production
World-wide except<@): January 1983 (us£): February 1983
om617 - 0310-1.jpg
A Garret turbocharger B KKK turbocharger

 

Removal
om617 - 0310-2.jpg
1 Remove air filter, detaching air filter cover and unscrewing 3 fastening nuts.
2        On vehicles with automatic climate control or air-conditioning remove electric line for
100° C temperature switch (1).
3        Release lower hose clip (arrow) on intake line (4) from air filter to compressor housing. On vehicles up to model 1979 only.
4        Remove vacuum line (2) and crankcase ventila­tion pipe (3).
5        Remove air filter with intake line (4).
om617 - 0310-3.jpg
1    Temperature switch 100 C
2    Vacuum line
3    Crankcase ventilation pipe
4    Intake line

 

09.8-430/1 F 3

 

 

6        Unscrew engine oil supply line (1).
7        Unscrew air filter holder (2). To do so, release 3 hex-head bolts (2 from above, 1 from below) and remove holder.
om617 - 0311-1.jpg
1    Engine oil supply line
2   Air filter holder

 

8        Unscrew exhaust flange (arrow).
9        Release and remove exhaust holder on auto­matic transmission.
10      Force exhaust pipe toward rear.
om617 - 0311-2.jpg

 

11      Unscrew holder (1) for adapter fitting (2).
12      Unscrew 4 fastening nuts (arrows) at exhaust-driven turbocharger and remove turbocharger.
13      Unscrew adapter fitting (2) at exhaust-driven turbocharger (3).
om617 - 0311-3.jpg
1    Holder
2   Adapter fitting
3   Turbocharger

 

09.8-430/2 F 3

 

 

14 Unscrew oil return pipe (92) at turbocharger.
om617 - 0312-1.jpg
60 Oil pan, upper part
90   Gasket
91    2 bolts M 8 x 20
92   Oil return pipe (upper part)
93   O-ring
94   Oil return pipe (lower part)
95   Sectional seal

 

Installation

 

Install in reverse order, using new gaskets (repair set). Please note the following points:
15 Prior to installing turbocharger, attach adapter fitting and oil return pipe. Correct positioning is absolutely essential.

 

16      Insert flange gasket between turbocharger and exhaust manifold so that bead (arrow) is at exhaust manifold side.
17      Always use heat-resistant nuts and bolts to
attach the turbocharger.
om617 - 0312-2.jpg

 

09.8-430/3 F 3

 

 

 

18 Prior to using a replacement turbocharger, fill with approx. 1/8 I engine oil through engine oil supply hole (arrow).
om617 - 0313-1.jpg

 

19 Make sure that intake line (4) is fitted in such a way that rubber sealing rings are correctly posi­tioned.
om617 - 0313-2.jpg
1    Temperature switch
2    Vacuum line
3    Ventilation pipe
4    Intake line

 

09.8-430/4 F 3

 

 

 

A. Exhaust Gas Turbocharger

 

om617 - 0314-1.jpg

 

1    Intake line
2    Hose clip
3    Rubber sealing ring
4    Turbocharger
5    Rubber sealing ring
6    Adapter fitting
7    Rubber sealing ring
8    Flange gasket
9    Heat-resistant nut                                        1 7
10   Washer                                                          18
11    Intake manifold                                           19
12    Pressure switch                                            21
13   Sealing ring                                                  22
14    Delivery line from intake manifold            23
15    Union screw                                                 70
16    Hose clip
Connecting hose
Switchover valve
Delivery line to aneroid compensator
Nut
Washer
Gasket
Aneroid compensator

 

09.8-430/5 F 3