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 .

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

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

-- 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.

Turbocharger Version 1

Fig 2: Identifying Crankcase Housing Ventilation

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

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

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

Fig 3: Identifying Oil Supply Line Bolts And Coolant Line Bolt

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

Turbocharger Version 2

Fig 4: Identifying Bolts

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

-- Press the release button and remove the hose -2-

-- Loosen the hose clamp -1-. Remove the air duct pipe.

-- Remove the banjo bolts -1 and 2- and bolts -3- and then move the lines to the side.

Fig 5: Identifying Banjo Bolts -1 And 2- And Bolts -3-

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Connector Bracket, Version 2

Fig 6: Identifying Heated Oxygen Sensor & Connector

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-- Remove the connector -arrow- for the Heated Oxygen Sensor -G39- and Oxygen Sensor Heater -Z19- and free up the wires.

Connector Bracket, Version 3

Fig 7: Oxygen Sensor Harness Connector

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-- Disconnect the connector -arrow- on the Oxygen Sensor after Three Way Catalytic Converter -G130- and free up the wires.

Continuation for All Vehicles

Fig 8: Identifying Heat Shield Components

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-- Remove the heat shield -arrows-.

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

Fig 9: Identifying Hose Clamp

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

Fig 10: Disconnect Connectors

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

Fig 11: Identifying Bolts

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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.

Fig 12: Identifying Clamping Sleeve Components

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

Fig 13: 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 14: Identifying Catalytic Converter

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

Fig 15: Identifying Catalytic Converter Flange Nuts

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-- Loosen the bolts -1- from above.

Fig 16: Identifying Turbocharger Support Bracket Bolts

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-- Remove the bolt -2- from below.

-- Remove the nuts -arrows-.

Fig 17: Identifying Turbocharger/Exhaust Manifold Nuts

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-- Remove the turbocharger with the exhaust manifold upward.