Turbocharger, Removing And Installing: Removing

NOTE:

Follow all the guidelines for clean working conditions. Refer to GUIDELINES FOR CLEAN WORKING CONDITIONS .

If mechanical damage (for example a destroyed compression wheel) is found on the turbocharger, just replacing the turbocharger is not enough. To avoid subsequent damage later, perform the following steps:

Check the air filter housing, air filter element and air duct 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.
Replace the oil screen -3- OVERVIEW - MECHANICAL CONTROL VALVE, CHECK VALVE, COVER IN INNER V => List Item:Oil Screen .

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 .

Continuation 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 .

Vehicles with the Engine Codes CGTA/CTFA/DDTA:

Fig 1: Identifying Left Air Guide Pipe And Clamps

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

Continuation for All Vehicles:

Fig 2: Identifying Left And Right Connectors

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

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

Fig 3: Identifying Heated Oxygen Sensors And Connectors

1 - For the Oxygen Sensor after Three Way Catalytic Converter -G130- -3-

4 - For the 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- .

NOTE:

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

Fig 4: Identifying Catalytic Converter Nuts

-- 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 5: Identifying Catalytic Converter Nuts

-- 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 and 7- , then remove the retaining plates -2 and 6- .

Fig 6: Identifying Retaining Plates And Bolts

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

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

Fig 7: Identifying Air Guide Hose, Clamp And Bolt

-- Remove the bolt -2- .

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

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

Fig 8: Identifying Lower Rear Coolant Pipe And Bolts

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

Fig 9: Identifying Turbocharger Support And Bolts

-- Lift up the spring -2- with a small screwdriver and remove the actuator rod -3- from the ball studs to remove the affected turbocharger actuator -23- OVERVIEW - TURBOCHARGER -List Item:Actuator Rod.

Fig 10: Detaching Gas-Filled Strut For Hood By Lifting Retaining Spring Using Small Screwdriver