Turbocharger, Removing And Installing: 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.
If there are foreign objects in the charge air system, clean the charge air circuit and replace the charge air cooler if necessary.

NOTE: Follow all the rules of cleanliness, refer to CLEAN WORKING CONDITIONS .

Left Turbocharger:

-- Remove the housing for the charge air cooler, refer to Removing .

Right Turbocharger:

-- Remove the right secondary air injection combination valve, refer to COMBINATION VALVE, REMOVING AND INSTALLING .

Continued for Both Sides:

-- Remove the left and right front muffler, refer to FRONT MUFFLER, REMOVING AND INSTALLING .

-- Remove the plenum chamber bulkhead, refer to Bulkhead .

-- Remove the connectors from the bracket, disconnect them and then free up the wires.

Fig 1: Identifying Connectors

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1 -

for Oxygen Sensor after Three Way Catalytic Converter -G130- item -3-

4 -

for Heated Oxygen Sensor -G39- item -2-

-- Free up the wiring harness for the Heated Oxygen Sensor 2 -G108- and Oxygen Sensor 2 after Catalytic Converter -G131-.

NOTE:

The catalytic converter for the cylinder bank 1 (right) is on the left in the vehicle.

Fig 2: Identifying Nuts

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-- Remove the nuts -arrows- from the cylinder bank 1 (right) and then remove the catalytic converter in the left of the vehicle, toward the rear.

NOTE:

The catalytic converter for the cylinder bank 2 (left) is on the right in the vehicle.

Fig 3: Identifying Nuts

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-- Remove the nuts -arrows- from the cylinder bank 2 (left) and then remove the catalytic converter on the right in the vehicle, toward the rear.

-- Remove the bolts -1, 4, 7-, then remove the retaining plates -2, 6-.

Fig 4: Identifying Retaining Plates And Bolts

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-- Remove the coolant lines -3, 5- from the left and right turbocharger.

-- Remove the bolts -1, 3- and then press the lower rear coolant pipe -2- toward the rear.

Fig 5: Identifying Lower Rear Coolant Pipe And Bolts

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-- Remove the bolts -1, 2, 3- and then remove the turbocharger support -4-.

Fig 6: Turbocharger Support - Tightening Specification and Sequence

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-- Lift up the spring -2- with a small screwdriver and remove the actuator rod -3- from the ball studs to remove the turbocharger actuator rod.

Fig 7: Identifying Retaining Spring, Screw Driver, And Gas-Filled Strut

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-- Disconnect the left and right connectors -1, 2-.

Fig 8: Identifying Left And Right Connectors

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-- Remove the bolts -arrows- and then remove the air guide pipe -1-.

Fig 9: Identifying Air Guide Pipe And Bolts

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Left Turbocharger:

Fig 10: Identifying Bolts And Hose Clamps

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-- Disconnect the connector -arrow-.

-- Remove the bolts -1, 3- and then remove the hose lines.

-- Loosen the hose clamps -2- to remove the oil return hose.

-- Remove the nuts in a -8 to 1- sequence and then remove the turbocharger.

Fig 11: Left Turbocharger - Tightening Specification and Sequence

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Right Turbocharger:

Fig 12: Identifying Connector And Bolts

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-- Disconnect the connector -arrow-.

-- Remove the bolts -1 and 2- and then remove the hose lines.

-- Loosen the hose clamps -3- to remove the oil return hose.

-- Remove the nuts in a -8 to 1- sequence and then remove the turbocharger.

Fig 13: Right Turbocharger - Tightening Specification and Sequence

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