Removal And Installation: Turbocharger

Special tools and workshop equipment required

Hose Clip Pliers VAS 6340
Open-end wrench (commercially available)

Removing

-- Observe rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

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 particulate filter. Refer to PARTICULATE FILTER .

-- Remove the air filter housing. Refer to Removal and Installation .

Fig 1: Identifying Air Filter Housing, Removal

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-- Free up the vacuum hoses -arrows- on the air guide pipe.

Fig 2: Identifying Air Guide Pipe

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-- Loosen the hose clamp -2- and remove the air guide pipe.

-- Press the release buttons and remove the crankshaft housing ventilation hose -2- from the cylinder head cover.

Fig 3: Identifying Electrical Connectors

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-- Free up the connector -1-, EGR temperature sensor -G98-.

-- Disconnect the connector -3-.

-- Remove the bolt -4-, turn the intake scoop clockwise and remove it.

-- Remove the bolt -1- and then remove warm air collector plate -arrow-.

Fig 4: Identifying Warm Air Collector Plate, Removal

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-- Remove the heat shield boot.

Fig 5: Identifying Turbocharger Vacuum Diaphragm

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-- Remove the vacuum hose -2- from the turbocharger vacuum diaphragm.

-- Disconnect the connector -1- on the charge pressure actuator position sensor -G581-.

-- Disconnect the -3- exhaust gas temperature sensor 1 -G235- connector and free up the wire.

Fig 6: Installed Locations and Connectors

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NOTE:

Ignore -1, 2, 4 and 5-.

-- Remove bolts -arrows-.

Fig 7: Identifying Left Air Guide Pipe

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-- Free up the electrical wires and the hoses on the left air guide pipe using the pry lever - rmv outside mirror 80 - 200.

-- Loosen the clamp -3- and push the left air guide pipe off the turbocharger and to the left.

NOTE:

Ignore -1, 2, 4 and 5-.

-- Remove the bolts -3- from the EGR vacuum regulator solenoid valve -N18-.

Fig 8: Identifying EGR Vacuum Regulator Solenoid Valve Bolts, Removal

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-- Remove the nuts -1-.

Fig 9: Identifying EGR Pipe, Removal

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-- Remove the bolt -2- and remove the EGR pipe -3-.

-- Loosen the union nut by counter holding it with an open-end wrench -3- and remove the oil supply line from the turbocharger connection.

Fig 10: Identifying Turbocharger Oil Supply Line

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NOTE:

Ignore -1 and 2-.

-- Remove the left and right coupling rod nuts -arrow- on the stabilizer bar.

Fig 11: Identifying Left/Right Coupling Rods From Stabilizer Bar

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-- Remove the nuts -arrows- on the right ball joint.

Fig 12: Identifying Ball Joint Lower Nuts

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-- Disengage the control arm from the right transverse link.

-- Move the right drive axle forward.

Fig 13: Identifying Drive Axle Secured To Longitudinal Member

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-- Secure the drive axle to the longitudinal member -arrow-.

NOTE:

Make sure the drive axle surface protection is not damaged.

-- Remove bolt -1-.

Fig 14: Identifying Exhaust Gas Temperature Sensor

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-- Mark the installed position of the exhaust gas temperature sensor 1 -2- and then free up its electrical wire.

-- Remove exhaust gas temperature sensor 1 -2- from the exhaust manifold with an open-end wrench.

-- Remove the nut -3- and the union nut -1- and then remove the control line.

Fig 15: Identifying Heat Shield, Removal

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-- Remove the nut -2- and then remove the heat shield.

-- Remove bolts -1-.

Fig 16: Identifying Turbocharger Support And Oil Return Pipe, Removal

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-- Remove the banjo bolt -3-. Then remove the turbocharger support and the oil return pipe.

-- Remove the bolts -arrows- and remove the turbocharger and the exhaust manifold from the cylinder head.

Fig 17: Identifying Turbocharger, Removal

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-- Remove the bolts -arrows- and then remove the bracket and heat shield.

Fig 18: Identifying Turbocharger Bracket And Heat Shield, Removal

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-- Push the engine/transmission subassembly slightly forward and remove the turbocharger and exhaust manifold downward.

Installing

Tightening specifications, refer to TURBOCHARGER ASSEMBLY OVERVIEW .

Installation is in reverse order of removal, note the following:

NOTE:

Replace the seals, O-rings and the self-locking nuts.

Fill the turbocharger with engine oil at the oil supply line connection.

The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing.

Secure all hose connections with hose clamps appropriate for the model.

In order to be able to securely mount the air guide hoses on their connectors, spray the screws on the previously used clamps with a rust remover.

To ensure the turbocharger is supplied with enough oil, let the engine run at idle for approximately 1 minute after installing the turbocharger. Do not increase the engine speed during this time.

During installation, the heat shield boots must be installed at the same location.

-- Install exhaust system and align it free of stress. Refer to EXHAUST SYSTEM, INSTALLING .

-- Install the transverse link and coupling rod. Refer to Removal and Installation .

-- Install the left air guide pipe. Refer to CHARGE AIR COOLER ASSEMBLY OVERVIEW .

-- Install air filter housing. Refer to Removal and Installation .

-- Install the particulate filter. Refer to PARTICULATE FILTER .

-- Check oil level. Refer to ENGINE, CHECKING OIL LEVEL