Turbocharger, Removing And Installing: Removing

NOTE:

Follow all the rules of cleanliness. Refer to CLEAN WORKING CONDITIONS .

Always seal off any open channels in the intake and exhaust tract with suitable plugs. For example, from the Engine Bung Set VAS6122.

CAUTION:

If mechanical damage (such as a destroyed compression wheel) is found on the turbocharger, just replacing the turbocharger is not enough. To avoid damage later, perform the following steps:

Check the air filter housing, air filter element and air guide hoses for contamination.
Check the entire charge air circuit and charge air cooler for foreign objects.
If there are foreign objects in the charge air system, clean the charge air circuit and replace the charge air cooler if necessary.

-- Remove the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

-- Remove the air filter housing. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

-- Drain the coolant. Refer to COOLANT, DRAINING AND FILLING .

-- Disconnect the coolant hose -arrow-.

Fig 1: Disconnecting Coolant Hose

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NOTE:

The engine is not shown in the illustrations that follow.

-- Remove the heat shield -arrows-.

Fig 2: Identifying Heat Shield Components

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-- Remove the crankcase housing ventilation -arrows- from the turbocharger.

Fig 3: Identifying Crankcase Housing Ventilation

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-- Remove the hose -1- from the turbocharger.

-- Remove the bolts -1 and 2- and move the oil supply line to the side.

Fig 4: Identifying Oil Supply Line Bolts

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-- Remove the bolt -3- and move the coolant line to the side.

-- Loosen the hose clamp -arrow-, pull of the air guide hose and move it to the side.

Fig 5: Identifying Hose Clamp

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-- Disconnect the connectors -1 and 2- and free up the wire.

Fig 6: Disconnect Connectors

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-- Remove the bolts -arrows- on the oil return line.

Fig 7: Identifying Oil Return Line Bolts

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Fig 8: Identifying Clamping Sleeve Components

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CAUTION:

The decoupling elements in the front muffler could be damaged.

Do not bend decoupling elements in front muffler more than 10°.

-- Loosen the threaded connections -arrows- and slide the clamping sleeves to the rear.

-- Slightly lower the front muffler and tie it to the crossbrace -arrow-.

Fig 9: Identifying Front Muffler Tied To Cossbrace

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-- Disconnect the threaded connection -1-, remove the bolt -2- and remove the catalytic converter mounting.

Fig 10: Identifying Catalytic Converter

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-- Remove the nuts -arrows- and push the catalytic converter to the rear.

Fig 11: Identifying Catalytic Converter Flange Nuts

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-- Loosen the bolts -1- from above.

Fig 12: Identifying Strut Bracket Bolts

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-- Remove the bolt -2- from below.

-- Remove the nuts -arrows-.

Fig 13: Identifying Turbocharger/Exhaust Manifold Nuts

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-- Remove the turbocharger with the exhaust manifold upward.