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 VAS 6122.

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 catalytic converter, refer to CATALYTIC CONVERTER, REMOVING AND INSTALLING .

-- Disconnect the connector -2- and free up the wire.

Fig 1: Identifying Mass Airflow Sensor Connector And Hose Clamp

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-- Open the clamp -3- and remove the air guide hose from the Mass Airflow Sensor -G70-.

NOTE:

Ignore item -1-.

-- Remove the air filter housing -1- upward.

Fig 2: Identifying Air Filter Housing

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-- Disconnect the coolant hose -arrow-.

Fig 3: Disconnecting Coolant Hose

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NOTE:

The engine is not shown in the illustrations that follow.

-- Remove the heat shield -arrows-.

Fig 4: Identifying Heat Shield Components

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Turbocharger Version 1

Fig 5: 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 6: Identifying Bolts

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

Turbocharger Version 2

Fig 7: 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 8: Identifying Banjo Bolts -1 And 2- And Bolts -3-

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

Fig 9: Identifying Heated Oxygen Sensor & Connector

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Continuation for All Vehicles

Fig 10: Identifying Hose Clamp

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

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

Fig 11: Disconnect Connectors

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-- Loosen the bolts -1- from above.

Fig 12: Identifying Bolts

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-- Remove the bolt -2- from below.

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

Fig 13: Identifying Bolts

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-- Remove the nuts -arrows-.

Fig 14: Identifying Turbocharger/Exhaust Manifold Nuts

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-- Remove the turbocharger with the exhaust manifold upward.