Removal And Installation: Turbocharger

Special tools and workshop equipment required

Hose Clip Pliers VAS 5024 A
Hex Ball Socket 3247
Engine Bung Set VAS 6122

CAUTION:

If mechanical damage is found on exhaust turbocharger, for example a destroyed compression wheel, it is not enough to just replace the turbocharger. Perform the following steps to prevent subsequent damage.

Check the air filter housing, the air filter insert and the intake hoses for contamination.
Check entire charge air circuit and cooler for contamination.

If contaminants are found in charge air circuit, circuit must be cleaned and cooler replaced if necessary.

Removing

-- Remove the engine cover and air filter. Refer to Removal and Installation .

WARNING:

Cover cap of expansion tank with rag and open carefully, as hot steam for example hot coolant may escape when opened.

-- Open cap of coolant expansion tank.

-- Drain the coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .

-- Pry off the caps on the wiper arms with a screwdriver and remove the nuts.

-- Pull off and remove wiper arms from wiper axles.

-- Unclip the spray nozzles -arrow-.

Fig 1: Removing Spray Nozzle

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-- Push the spray nozzles, with lines still attached, back through the opening and into the plenum chamber.

-- Remove rubber seal -1- for plenum chamber cover.

Fig 2: Plenum Chamber Cover And Rubber Seal

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-- Remove the plenum chamber cover -2-.

-- Free up the rear engine wiring harness at the partition for plenum chamber.

-- Remove electrical connector -arrow- for heated oxygen sensor (HO2S) -G39- and oxygen sensor (O2S) heater -Z19- before catalytic converter from the bracket, disconnect it and lay it aside.

Fig 3: Disconnecting Heated Oxygen Sensor (HO2S) G39 Harness Connector

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-- Remove partition for plenum chamber -arrows-.

Fig 4: Plenum Chamber Partition

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-- Disconnect connector -1- from ignition coils.

Fig 5: Identifying Crankcase Ventilation Line Between High Pressure Pump And Cylinder Crankcase

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NOTE:

The illustration depicts the engine removed from behind.

-- Remove the heat shield -arrows-.

Fig 6: Heat Shield Bolts

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-- Disconnect the coolant line to coolant expansion tank -arrow-.

Fig 7: Disconnecting Coolant Line To Coolant Expansion Tank

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-- Disconnect coolant hose -1-.

Fig 8: Identifying Coolant Hoses

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-- Disconnect coolant hose -2-.

-- Remove coolant pipe bracket -3-.

-- Remove crankcase ventilation line with heat shield from turbocharger -1-.

Fig 9: Identifying Crankcase Ventilation With Heat Shield, Crankcase Ventilation From Cylinder Head Cover, Oil Supply Line & EVAP Canister Line

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-- Pull off the crankcase ventilation line from the cylinder head cover -2- and remove it.

-- Disconnect EVAP line to turbocharger from cylinder head cover -3-.

-- Remove oil supply line from turbocharger -4-.

-- Remove catalytic converter with front exhaust pipe. Refer to FRONT EXHAUST PIPE WITH CATALYTIC CONVERTERS AND FRONT MUFFLER .

-- Remove noise insulation. Refer to Removal and Installation .

-- Remove right noise insulation fasteners -1 to 3-.

Fig 10: Identifying Fasteners

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-- Remove right drive axle. Refer to Removal and Installation .

-- Remove the right drive axle heat shield -arrows-.

Fig 11: Identifying Protective Cap For Drive Axle On Engine

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-- Disconnect air guide pipe -arrow- from charge air cooler.

Fig 12: Charge Air Cooler Air Guide Pipe

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-- Unfasten air duct from turbocharger -arrows-.

Fig 13: Turbocharger Air Duct And Connector

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-- Disconnect the connector -1 and 2- and free up the cable.

-- Remove bolts -arrows- and remove air guide pipe.

Fig 14: Identifying Charge Air Pipe Bolts

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NOTE:

The illustration depicts the engine removed from behind.

-- Remove the oil supply line from the turbocharger -2-.

Fig 15: Cylinder Block And Turbocharger Oil Supply Line

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-- Remove coolant supply line to turbocharger -2-.

Fig 16: Turbocharger Coolant Supply Line Connections

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-- Disconnect oil return line -arrows- on turbocharger.

Fig 17: Identifying Oil Return Line

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-- Remove bolts -1- and -2- and remove support for turbocharger.

Fig 18: Identifying Bolts And Support For Turbocharger

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-- Disconnect coolant pipe -arrow-.

Fig 19: Coolant Pipe

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NOTE:

The illustration depicts the engine removed from behind.

The nuts on the fastening strip do not need to be opened.

-- If present, remove coolant pipe bolt -1- from cylinder head.

Fig 20: Identifying Bolt For Coolant Pipe And Top Nuts

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-- Remove the upper nuts -arrows-.

-- Remove turbocharger/exhaust manifold upward.

Installing

Install in reverse order of removal. Note the following:

For the correct tightening specifications, refer to TURBOCHARGER OVERVIEW

NOTE:

Always replace seals, gaskets and self-locking nuts.

Add oil to turbocharger through oil feed line connecting piece.

Hose connections and charge air system hoses must be free of oil and grease before installing.

Secure all hose connections using hose clamps appropriate for the model type.

-- Install exhaust system and align it free of tension. Refer to EXHAUST SYSTEM, ALIGNING .

-- Install drive axle. Refer to Removal and Installation .

-- Install air guide pipes and connector. Refer to HOSE CONNECTIONS WITH CONNECTOR COUPLINGS .

-- Fill with coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .

-- Check oil level. Refer to Maintenance Procedures Rep. Gr. 03.

NOTE:

After installing turbocharger, let engine idle for approximately 1 minute without increasing engine speed. This ensures adequate oil supply to the turbocharger.