Removal And Installation: Turbocharger

Special tools and workshop equipment required

Engine Bung Set VAS 6122
Hose Clip Pliers VAS 6362

Removing

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.
Clean the charge air circuit if foreign objects are found in the charge air system. Replace the charge air cooler if necessary.

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

-- Remove the noise insulation frame -arrow- with the rear noise insulation. Refer to Removal and Installation .

Fig 1: Identifying Noise Insulation Frame

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-- Remove the temperature sensor for exhaust gas temperature sensor 1 -G235- -arrow-.

Fig 2: Identifying Exhaust Gas Temperature Sensor 1

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-- Remove the Heated Oxygen Sensor (HO2S) -G39-. Refer to Removal and Installation .

-- Remove the high pressure pump. Refer to Removal and Installation .

-- Remove the bolts -1 and 2-.

Fig 3: Identifying Air Guide Pipe

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-- Remove the air guide pipe, to do this, loosen the hose clamps -arrows-.

NOTE:

Lay a cloth below to catch escaping coolant and engine oil.

Fig 4: Locating High Pressure Pump Bolts

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-- Remove bolts -1, 2, 3- and banjo bolt -4- and remove wires from the cylinder block.

-- Seal off the openings on the turbocharger and on the charge air pipe VAS 6122.

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

Fig 5: Identifying Air Filter Housing Component Location

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Vehicles with a Manual Transmission:

Fig 6: Disconnecting Cable Retainer From Selector Cable

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-- Pull the safety mechanism all the way to the front -arrow 1- and then lock it to the left -arrow 2-.

-- Push the shift relay lever forward -arrow 3- and remove the selector cable from the retainer.

-- Remove the lock washer -1- for the shift cable from the transmission selector lever -2- and remove the shift cable from the pin -arrow-.

Fig 7: Identifying Shift Cable To Gearshift Lever, Removing And Securing

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-- Remove the bolts -arrows-, then remove the cable bracket from the transmission and tie it up to the left.

Fig 8: Locating Transmission Cable Bracket Bolts

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-- Loosen the clamp -1- and remove the coolant hose.

Fig 9: Locating Coolant Hose Clamps

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NOTE:

Ignore -2-.

-- Remove the vacuum hose -1- from the non-return valve -arrow-.

Fig 10: Identifying Non-Return Valve Vacuum Hose

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-- Remove the check valve from the brake booster.

-- Disconnect the connectors -1 and 2-.

Fig 11: Locating Connectors & Bolts

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-- Remove the bolts -3- and remove the supports from the cylinder head cover.

-- Disconnect the connector -1- on the wastegate bypass regulator valve -N75- and free up the wire.

Fig 12: Locating Wastegate Bypass Regulator Valve Connector

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-- Remove hose and loosen the hose clamp -arrows- and -2-.

-- Remove bolts -3- and lay the intake tube toward the rear.

-- Free up the wiring harness on the heat shield -1-.

Fig 13: Identifying Heat Shield Wiring Harness

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

-- Remove the intake tube.

-- Loosen the bolt -3- and slide the clamp onto the primary catalytic converter.

Fig 14: Identifying Intake Tube

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-- Remove the bolt -2- and tie up the primary catalytic converter toward the rear.

NOTE:

Ignore -1-.

-- Remove the bolts -arrows- and the cross brace -1-.

Fig 15: Identifying Mount -3- And Crossbrace -1

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NOTE:

Ignore -2 and 3-.

-- Remove the bolts -arrows-.

Fig 16: Locating Coolant Hose Bolts

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-- Loosen the clamp -1- and remove the coolant hose.

-- Remove cylinder head cover. Refer to CYLINDER HEAD COVER .

-- Remove the nuts in sequence -6 to 1- and then remove the turbocharger.

Fig 17: Identifying Turbocharger - Tightening Specification and Sequence

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-- Seal any open lines and connections with a clean plug from the VAS 6122.

Installing

Install in reverse order, paying attention to the following:

Tightening specifications:

NOTE:

Replace the seals and O-rings.

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 of the same type as those equipped by the factory.

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.

-- Install cylinder head cover. Refer to CYLINDER HEAD COVER .

-- Install heated oxygen sensor and high pressure pump. Refer to Removal and Installation .

-- Install the exhaust gas temperature sensor 1 -G235-. Refer to Exhaust Gas Temperature (EGT) Sensor 1 -G235- .

-- Install the air guide pipes. Refer to CHARGE AIR COOLER OVERVIEW .

-- Selector mechanism, installing and adjusting. Refer to Removal and Installation .

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

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

-- Install the noise insulation frame. Refer to Removal and Installation .

-- Fill the engine with coolant. Refer to COOLANT, DRAINING AND FILLING => Filling .

NOTE:

If the turbocharger is replaced, it must be guaranteed that the auxiliary engine coolant pump relay -J496-, after-run coolant pump -V51- and cooling circuit solenoid valve -N492- are functioning properly. The after-run coolant pump is contained in the fault finding programs for the auxiliary engine coolant pump relay, there is a separate fault finding programs for the cooling circuit solenoid valve.