900049 Type Type description MY Engine ID Gearbox ID User Workshop Manual

3A AAZ with turbocharger

Charge air system CHA --- -1-

Removing and installing turbocharger with attachments

Observe rules for cleanliness => Page 21-16.

Engine code 1Z, AHU =>Page 21-2

Engine code AFN =>Page 21-6

Engine code AAZ =>Page 21-9

Turbocharger hose connections => Page 21-17.

Notes:

‹ All hose connections are secured with clips.

‹ Charge air system must be free of leaks.

‹ Renew self-locking nuts.

900049 Type Type description MY Engine ID Gearbox ID User Workshop Manual
3A AAZ CHA
Engine code 1Z, AHU--- -2-

1 - Exhaust manifold

2 - 35 Nm
‹ Renew
‹ Coat threads and bolt head seating surface with G000500

3 - Intake manifold

4 - From charge air cooler

5 - Hose
‹ Black
‹ To diesel direct injection system control unit (J248)

6 - Gasket
‹ Renew
‹ Coating (beading) towards intake manifold

7 - 25 Nm
900049 Type Type description MY Engine ID Gearbox ID User Workshop Manual
3A AAZ CHA --- -3-
900049 Type Type description MY Engine ID Gearbox ID User Workshop Manual
3A AAZ CHA --- -4-
8 - Gasket
‹ Note installation position

9 - 25 Nm

10 - 10 Nm
‹ Install with D6

11 - Circlip

12 - Pressure unit
‹ For charge pressure regulating valve
‹ Checking =>Page 21-33
‹ Removing and installing
=> Page 21-34

13 - Hose
‹ Blue
‹ To charge pressure control solenoid valve (N75) => Page
21-17, turbocharger hose connections

14 - Oil seal
‹ Renew
900049 Type Type description MY Engine ID Gearbox ID User Workshop Manual
3A AAZ CHA --- -5-
900049 Type Type description MY Engine ID Gearbox ID User Workshop Manual
3A AAZ CHA --- -6-
15 - Banjo bolt, 15 Nm

16 - From air cleaner

17 - O ring
‹ Renew if damaged

18 - 10 Nm

19 - Banjo bolt, 30 Nm

20 - Oil return pipe

‹ To cylinder block

21 - 30 Nm

22 - Gasket
‹ Renew

23 - Retainer

24 - Hose
‹ rot
‹ To charge pressure control solenoid valve (N75) => Page
21-17, turbocharger hose connections
900049 Type Type description MY Engine ID Gearbox ID User Workshop Manual
3A AAZ CHA --- -7-
900049 Type Type description MY Engine ID Gearbox ID User Workshop Manual
3A AAZ CHA --- -8-
25 - Turbocharger
‹ Removing and installing
=> Page 21-20
‹ Checking boost pressure
=> Page 21-28

26 - To charge air cooler

27 - Front exhaust pipe

28 - Oil supply pipe

‹ From oil filter bracket
=> Page , item

29 - Heat shield
900049 Type Type description MY Engine ID Gearbox ID User Workshop Manual
3A AAZ CHA --- -9-
900049 Type Type description MY Engine ID Gearbox ID User Workshop Manual
3A AAZ CHA
Engine code AFN --- - 10 -

1 - Exhaust manifold

2 - Intake manifold
‹ With exhaust gas recirculation valve

3 - From charge air cooler

4 - Gasket
‹ Renew
‹ Coating (beading) towards intake manifold

5 - 25 Nm

6 - Gasket
‹ Note installation position

7 - Bracket
‹ For heat shield item 12

8 - Washer

9 - From air cleaner

10 - 10 Nm
900049 Type Type description MY Engine ID Gearbox ID User Workshop Manual
3A AAZ CHA --- - 11 -
11 - Hose
‹ To charge pressure control solenoid valve (N75) => Page
21-17, turbocharger hose connections

12 - Heat shield
‹ Engage in bracket item 7

13 - Turbocharger
‹ Removing and installing
=> Page 21-20
‹ Checking charge pressure
=> Repair group 23; Servicing diesel direct injection system;
Checking charge pressure system=>

14 - Pressure unit
‹ For charge pressure control
‹ Integral part of turbocharger cannot be replaced

15 - O ring
‹ Renew if damaged

16 - Oil seal
‹ Renew
900049 Type Type description MY Engine ID Gearbox ID User Workshop Manual
3A AAZ CHA --- - 12 -
17 - Banjo bolt, 30 Nm

18 - Oil return pipe

‹ To cylinder block

19 - 30 Nm

20 - Gasket
‹ Renew

21 - 30 Nm

22 - Retainer

23 - To charge air cooler

24 - Front exhaust pipe

25 - Oil supply pipe

‹ From oil filter bracket
=> Page , item

26 - 25 Nm
‹ Renew
‹ Coat threads and bolt head seating surface with G 000 500
900049 Type Type description MY Engine ID Gearbox ID User Workshop Manual
3A AAZ CHA
Engine code AAZ --- - 13 -

Note:

‹ The charge pressure control is switched off during partial

throttle operations by exhaust gas recirculation partial throttle
switch (F166) and the exhaust gas recirculation two-way valve
(N161).

‹ Checking and adjusting partial throttle switch =>Page 26-30

‹ Checking two-way valve

=> Page 26-28

1 - Exhaust manifold

2 - 25 Nm

3 - Hose
‹ To injection pump

4 - Gasket
‹ Renew
‹ Coating (beading) towards intake manifold
900049 Type Type description MY Engine ID Gearbox ID User Workshop Manual
3A AAZ CHA --- - 14 -
5 - Intake manifold

6 - 45 Nm
‹ Renew
‹ Coat threads and bolt head seating surface with G000500

7 - Gasket
‹ Renew
‹ Note installation position

8 - To crankcase breather

9 - From air cleaner

10 - Turbocharger
‹ Removing and installing
=> Page 21-20
‹ Checking boost pressure
=> Page 21-28

11 - Wastegate
‹ Integral part of turbocharger cannot be replaced
‹ Hose/pipe connections
=> Page 21-17
900049 Type Type description MY Engine ID Gearbox ID User Workshop Manual
3A AAZ CHA --- - 15 -
12 - Oil return pipe
‹ To cylinder block

13 - Sealing ring
‹ Renew

14 - Banjo bolt, 30 Nm

15 - 30 Nm

16 - Front exhaust pipe

17 - Oil supply pipe

‹ From oil filter bracket
=> Page , item

18 - Air hose

19 - Retainer
‹ Between exhaust pipe and exhaust manifold