{"id":2949,"date":"2023-11-18T00:14:51","date_gmt":"2023-11-17T23:14:51","guid":{"rendered":"https:\/\/mbci.mackuz.ovh\/?p=2949"},"modified":"2023-11-18T00:17:04","modified_gmt":"2023-11-17T23:17:04","slug":"removal-and-installation-of-exhaust-gas-turbocharger","status":"publish","type":"post","link":"https:\/\/mbci.mackuz.ovh\/index.php\/2023\/11\/18\/removal-and-installation-of-exhaust-gas-turbocharger\/","title":{"rendered":"Removal and installation of exhaust gas turbocharger"},"content":{"rendered":"

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09\u2014430 Removal and installation of exhaust gas turbocharger<\/strong><\/div>\n<\/div>\n<\/td>\n
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Turbocharger designation<\/strong><\/div>\n<\/div>\n<\/td>\n
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Garret<\/div>\n<\/div>\n<\/td>\n
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TA 0301<\/div>\n<\/div>\n<\/td>\n
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Kiihnle Kopp and Kausch KKK 532 679 60 31;<\/sup><\/div>\n<\/div>\n<\/td>\n
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x<\/sup>) Start of production<\/strong><\/div>\n
World-wide except<@): January 1983 (us\u00a3): February 1983<\/div>\n<\/div>\n<\/td>\n
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\"om617<\/div>\n<\/td>\n
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A Garret turbocharger B KKK turbocharger<\/div>\n<\/div>\n<\/td>\n
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Removal<\/strong><\/div>\n<\/div>\n<\/td>\n
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1 <\/strong>Remove air filter, detaching air filter cover and unscrewing 3 fastening nuts.<\/div>\n<\/div>\n<\/td>\n
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2\u00a0 \u00a0 \u00a0 \u00a0 On vehicles with automatic climate control or air-conditioning remove electric line for<\/div>\n
100\u00b0 C temperature switch (1).<\/div>\n
3\u00a0 \u00a0 \u00a0 \u00a0 Release lower hose clip (arrow) on intake line (4) from air filter to compressor housing. On vehicles up to model 1979 only.<\/div>\n
4\u00a0 \u00a0 \u00a0 \u00a0 Remove vacuum line (2) and crankcase ventila\u00adtion pipe (3).<\/div>\n
5\u00a0 \u00a0 \u00a0 \u00a0 Remove air filter with intake line (4).<\/div>\n<\/div>\n<\/td>\n
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1\u00a0 \u00a0 Temperature switch 100 C<\/div>\n
2\u00a0 \u00a0 Vacuum line<\/div>\n
3\u00a0 \u00a0 Crankcase ventilation pipe<\/div>\n
4\u00a0 \u00a0 Intake line<\/div>\n<\/div>\n<\/td>\n
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09.8-430\/1 F 3<\/div>\n<\/div>\n<\/td>\n
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6\u00a0 \u00a0 \u00a0 \u00a0 Unscrew engine oil supply line (1).<\/div>\n
7\u00a0 \u00a0 \u00a0 \u00a0 Unscrew air filter holder (2). To do so, release 3 hex-head bolts (2 from above, 1 from below) and remove holder.<\/div>\n<\/div>\n<\/td>\n
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1\u00a0 \u00a0 Engine oil supply line<\/div>\n
2\u00a0 \u00a0Air filter holder<\/div>\n<\/div>\n<\/td>\n
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8\u00a0 \u00a0 \u00a0 \u00a0 Unscrew exhaust flange (arrow).<\/div>\n
9\u00a0 \u00a0 \u00a0 \u00a0 Release and remove exhaust holder on auto\u00admatic transmission.<\/div>\n
10\u00a0 \u00a0 \u00a0 Force exhaust pipe toward rear.<\/div>\n<\/div>\n<\/td>\n
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11\u00a0 \u00a0 \u00a0 Unscrew holder (1) for adapter fitting (2).<\/div>\n
12\u00a0 \u00a0 \u00a0 Unscrew 4 fastening nuts (arrows) at exhaust-driven turbocharger and remove turbocharger.<\/div>\n
13\u00a0 \u00a0 \u00a0 Unscrew adapter fitting (2) at exhaust-driven turbocharger (3).<\/div>\n<\/div>\n<\/td>\n
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1\u00a0 \u00a0 Holder<\/div>\n
2\u00a0 \u00a0Adapter fitting<\/div>\n
3\u00a0 \u00a0Turbocharger<\/div>\n<\/div>\n<\/td>\n
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09.8-430\/2 F 3<\/div>\n<\/div>\n<\/td>\n
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14 Unscrew oil return pipe (92) at turbocharger.<\/div>\n<\/div>\n<\/td>\n
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60 Oil pan, upper part<\/div>\n
90\u00a0 \u00a0Gasket<\/div>\n
91\u00a0 \u00a0 2 bolts M 8 x 20<\/div>\n
92\u00a0 \u00a0Oil return pipe (upper part)<\/div>\n
93\u00a0 \u00a0O-ring<\/div>\n
94\u00a0 \u00a0Oil return pipe (lower part)<\/div>\n
95\u00a0 \u00a0Sectional seal<\/div>\n<\/div>\n<\/td>\n
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Installation<\/strong><\/div>\n<\/div>\n<\/td>\n
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Install in reverse order, using new gaskets (repair set). Please note the following points:<\/div>\n
15 Prior to installing turbocharger, attach adapter fitting and oil return pipe. Correct positioning is absolutely essential.<\/div>\n<\/div>\n<\/td>\n
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16\u00a0 \u00a0 \u00a0 Insert flange gasket between turbocharger and exhaust manifold so that bead (arrow) is at exhaust manifold side.<\/div>\n
17\u00a0 \u00a0 \u00a0 Always use heat-resistant nuts and bolts <\/strong>to<\/div>\n
attach the turbocharger.<\/div>\n<\/div>\n<\/td>\n
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09.8-430\/3 F 3<\/div>\n<\/div>\n<\/td>\n
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18 Prior to using a replacement turbocharger, fill with approx. 1\/8 I engine oil through engine oil supply hole (arrow).<\/div>\n<\/div>\n<\/td>\n
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19 Make sure that intake line (4) is fitted in such a way that rubber sealing rings are correctly posi\u00adtioned.<\/div>\n<\/div>\n<\/td>\n
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1\u00a0 \u00a0 Temperature switch<\/div>\n
2\u00a0 \u00a0 Vacuum line<\/div>\n
3\u00a0 \u00a0 Ventilation pipe<\/div>\n
4\u00a0 \u00a0 Intake line<\/div>\n<\/div>\n<\/td>\n
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09.8-430\/4 F 3<\/div>\n<\/div>\n<\/td>\n
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A. Exhaust Gas Turbocharger<\/strong><\/div>\n<\/div>\n<\/td>\n
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1\u00a0 \u00a0 Intake line<\/div>\n
2\u00a0 \u00a0 Hose clip<\/div>\n
3\u00a0 \u00a0 Rubber sealing ring<\/div>\n
4\u00a0 \u00a0 Turbocharger<\/div>\n
5\u00a0 \u00a0 Rubber sealing ring<\/div>\n
6\u00a0 \u00a0 Adapter fitting<\/div>\n
7\u00a0 \u00a0 Rubber sealing ring<\/div>\n
8\u00a0 \u00a0 Flange gasket<\/div>\n<\/div>\n<\/td>\n
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9\u00a0 \u00a0 Heat-resistant nut\u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 1 7<\/div>\n
10\u00a0 \u00a0Washer\u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 18<\/div>\n
11\u00a0 \u00a0 Intake manifold\u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a019<\/div>\n
12\u00a0 \u00a0 Pressure switch\u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 21<\/div>\n
13\u00a0 \u00a0Sealing ring\u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 22<\/div>\n
14\u00a0 \u00a0 Delivery line from intake manifold\u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 23<\/div>\n
15\u00a0 \u00a0 Union screw\u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a070<\/div>\n
16\u00a0 \u00a0 Hose clip<\/div>\n<\/div>\n<\/td>\n
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Connecting hose<\/div>\n
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Delivery line to aneroid compensator<\/div>\n
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    09\u2014430 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\u00a3): February 1983 A Garret turbocharger B KKK turbocharger   Removal 1 Remove air filter, detaching air filter cover and unscrewing 3 fastening nuts. 2\u00a0 \u00a0 \u00a0 \u00a0 On vehicles with automatic climate control or air-conditioning remove electric line for 100\u00b0 C temperature switch (1). 3\u00a0 \u00a0 \u00a0 \u00a0 Release lower hose clip (arrow) on intake line (4) from air filter to compressor housing. On vehicles up to model 1979 only. 4\u00a0 \u00a0 \u00a0 \u00a0 Remove vacuum line (2) and crankcase ventila\u00adtion pipe (3). 5\u00a0 \u00a0 \u00a0 \u00a0 Remove air filter with intake line (4). 1\u00a0 \u00a0 Temperature switch 100 C 2\u00a0 \u00a0 Vacuum line 3\u00a0 \u00a0 Crankcase ventilation pipe 4\u00a0 \u00a0 Intake line   09.8-430\/1 F 3     6\u00a0 \u00a0 \u00a0 \u00a0 Unscrew engine oil supply line (1). 7\u00a0 \u00a0 \u00a0 \u00a0 Unscrew air filter holder (2). To do so, release 3 hex-head bolts (2 from above, 1 from below) and remove holder. 1\u00a0 \u00a0 Engine oil supply line 2\u00a0 \u00a0Air filter holder   8\u00a0 \u00a0 \u00a0 \u00a0 Unscrew exhaust flange (arrow). 9\u00a0 \u00a0 \u00a0 \u00a0 Release and remove exhaust holder on auto\u00admatic transmission. 10\u00a0 \u00a0 \u00a0 Force exhaust pipe toward rear.   11\u00a0 \u00a0 \u00a0 Unscrew holder (1) for adapter fitting (2). 12\u00a0 \u00a0 \u00a0 Unscrew 4 fastening nuts (arrows) at exhaust-driven turbocharger and remove turbocharger. 13\u00a0 \u00a0 \u00a0 Unscrew adapter fitting (2) at exhaust-driven turbocharger (3). 1\u00a0 \u00a0 Holder 2\u00a0 \u00a0Adapter fitting 3\u00a0 \u00a0Turbocharger   09.8-430\/2 F 3     14 Unscrew oil return pipe (92) at turbocharger. 60 Oil pan, upper part 90\u00a0 \u00a0Gasket 91\u00a0 \u00a0 2 bolts M 8 x 20 92\u00a0 \u00a0Oil return pipe (upper part) 93\u00a0 \u00a0O-ring 94\u00a0 \u00a0Oil return pipe (lower part) 95\u00a0 \u00a0Sectional 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\u00a0 \u00a0 \u00a0 Insert flange gasket between turbocharger and exhaust manifold so that bead (arrow) is at exhaust manifold side. 17\u00a0 \u00a0 \u00a0 Always use heat-resistant nuts and bolts to attach the turbocharger.   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).   19 Make sure that intake line (4) is fitted in such a way that rubber sealing rings are correctly posi\u00adtioned. 1\u00a0 \u00a0 Temperature switch 2\u00a0 \u00a0 Vacuum line 3\u00a0 \u00a0 Ventilation pipe 4\u00a0 \u00a0 Intake line   09.8-430\/4 F 3       A. Exhaust Gas Turbocharger     1\u00a0 \u00a0 Intake line 2\u00a0 \u00a0 Hose clip 3\u00a0 \u00a0 Rubber sealing ring 4\u00a0 \u00a0 Turbocharger 5\u00a0 \u00a0 Rubber sealing ring 6\u00a0 \u00a0 Adapter fitting 7\u00a0 \u00a0 Rubber sealing ring 8\u00a0 \u00a0 Flange gasket 9\u00a0 \u00a0 Heat-resistant nut\u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 1 7 10\u00a0 \u00a0Washer\u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 18 11\u00a0 \u00a0 Intake manifold\u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a019 12\u00a0 \u00a0 Pressure switch\u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 21 13\u00a0 \u00a0Sealing ring\u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 22 14\u00a0 \u00a0 Delivery line from intake manifold\u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 23 15\u00a0 \u00a0 Union screw\u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a070 16\u00a0 \u00a0 Hose clip Connecting hose Switchover valve Delivery line to aneroid compensator Nut Washer Gasket Aneroid compensator   09.8-430\/5 F 3      <\/p>\n","protected":false},"author":1,"featured_media":0,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_crdt_document":"","footnotes":""},"categories":[59,44],"tags":[],"class_list":["post-2949","post","type-post","status-publish","format-standard","hentry","category-exhaust-system","category-om617"],"aioseo_notices":[],"featured_image_src":null,"author_info":{"display_name":"mackuz","author_link":"https:\/\/mbci.mackuz.ovh\/index.php\/author\/mackuz\/"},"_links":{"self":[{"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/posts\/2949","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/comments?post=2949"}],"version-history":[{"count":1,"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/posts\/2949\/revisions"}],"predecessor-version":[{"id":2950,"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/posts\/2949\/revisions\/2950"}],"wp:attachment":[{"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/media?parent=2949"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/categories?post=2949"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/tags?post=2949"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}