Turbocharger, Removing And Installing: Removing

NOTE:

Follow all the rules of 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.

Left Turbocharger:

-- Remove the housing for the charge air cooler, refer to CHARGE AIR COOLER HOUSING, REMOVING AND INSTALLING .

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 OVERVIEW - BULKHEAD .

Vehicles with the Engine Codes CGTA/CTFA:

-- Loosen the clamps -arrows- and remove the left air guide pipe.

Fig 1: Identifying Left Air Guide Pipe And Clamps

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Continuation for All Vehicles:

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

Fig 2: Identifying Left And Right Connectors

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

1 -

for Oxygen Sensor After Three Way Catalytic Converter -G130- -3-

4 -

for Heated Oxygen Sensor -G39- -2-

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

Fig 3: Identifying Oxygen Sensor After Three Way Catalytic Converter Connector And Bracket

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NOTE:

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

-- 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.

Fig 4: Identifying Catalytic Converter Nuts

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NOTE:

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

-- 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.

Fig 5: Identifying Catalytic Converter Nuts

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

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

Fig 6: Identifying Retaining Plates And Bolts

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-- Loosen the clamp -1- and remove the air guide hose.

-- Remove the bolt -2-.

-- Free up the vacuum line and press it toward the rear.

Fig 7: Identifying Air Guide Hose, Clamp And Bolt

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

Fig 8: 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 9: Identifying Turbocharger Support And Bolts

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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 in question.

Fig 10: Identifying Retaining Spring, Screw Driver, And Turbocharger Actuator Rod