Turbocharger, Removing And Installing, Engine Codes CRFA And CRFC

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.

Special tools and workshop equipment required 

• Hose Clip Pliers: VAS 6362 
  Fig 1: Hose Clip Pliers

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• Socket Bit XZN 10: T10501 
  Fig 2: Identifying Socket Bit

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-- Remove the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

-- Drain the coolant. Refer to COOLANT, DRAINING AND FILLING WITHOUT Cooling System Charge Kit - Electric Vacuum Pump .

-- Remove the front exhaust pipe. Refer to FRONT EXHAUST PIPE, REMOVING AND INSTALLING .

-- Remove the rear coolant pipe. Refer to REAR COOLANT PIPE, REMOVING AND INSTALLING .

Vehicles with Parking Heater: 

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-- Lift the clamps -1-, loosen the hose clamp -2- and remove the coolant hoses.

-- Remove the nuts -arrows- and the coolant pipes.

-- Press the release buttons on the crankcase ventilation hose -1- and remove from the cylinder head cover.

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-- Free up the vacuum hose on the air duct pipe -arrows-.

-- Remove the bolt -2- and pivot the air duct pipe with the intake tube toward the rear and remove it from the turbocharger.

-- Remove the bolts -arrows- and remove the resonator -1-.

Fig 3: Identifying Resonator With Bolts

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-- Disconnect the connector -1- from the Exhaust Gas Temperature Sensor 1 -G235-.

Fig 4: Identifying Connector

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-- Remove the catalytic converter or the particulate filter. Refer to PARTICULATE FILTER, REMOVING AND INSTALLING (NOT FOR NORTH AMERICA MARKET) .

-- Remove the EGR cooler. Refer to EGR COOLER, REMOVING AND INSTALLING, EU 4 (NOT FOR NORTH AMERICA MARKET) .

-- Remove the bolts -1 through 5- and remove the EGR cooler bracket.

Fig 5: EGR Cooler Bracket Tightening Sequence

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-- Remove the bolt -2- and union nut -4-.

Fig 6: Identifying Bolts

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-- Remove the bolts -3 and 5- and the oil return pipe.

-- Remove the bolts -arrows- and remove the heat shield -1-.

Fig 7: Identifying Heat Shield Bolts

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-- Remove the vacuum hose -2- from the turbocharger vacuum diaphragm.

Fig 8: Identifying Vacuum Hose

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-- Remove the nuts -arrows- and remove the turbocharger with the exhaust manifold from the cylinder head upward.

Fig 9: Identifying Nuts

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Installing 

Install in the reverse order of removal while noting the following:

• Replace seals, gaskets, O-rings and self-locking nuts after disassembly.
• Fill the turbocharger with engine oil at the oil supply line connection.
• The hose connections as well as air duct pipes and hoses must be free of oil and grease before installing.
• Secure all hose connections with hose clamps that match the ones used in series production. Refer to the Parts Information.
• To ensure the turbocharger is supplied with enough oil, let the engine run at idle for approximately one minute after installing the turbocharger. Do not increase the engine speed.

-- Electrical connections and routing. Refer to OVERVIEW - RELAY CARRIERS, FUSE PANELS AND E-BOXES and the appropriate Wiring Diagram.

-- Install the rear coolant pipe. Refer to REAR COOLANT PIPE, REMOVING AND INSTALLING .

-- Install the EGR cooler bracket. Refer to Fig 10.

Fig 10: EGR Cooler Bracket Tightening Sequence

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-- Install the EGR cooler. Refer to EGR COOLER, REMOVING AND INSTALLING, EU 4 (NOT FOR NORTH AMERICA MARKET) .

-- Install the catalytic converter and/or particulate filter. Refer to PARTICULATE FILTER, REMOVING AND INSTALLING (NOT FOR NORTH AMERICA MARKET) .

-- Install the front exhaust pipe. Refer to FRONT EXHAUST PIPE, REMOVING AND INSTALLING .

-- Install the vacuum hose. Refer to CONNECTION DIAGRAM - VACUUM SYSTEM .

-- Install the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

After replacing components, perform the necessary adaptations using the Vehicle Diagnostic Tester. Refer to PERFORM ADAPTATIONS AFTER COMPONENT REPLACEMENT .

Tightening Specifications 

• Refer to OVERVIEW - TURBOCHARGER 
• Refer to OVERVIEW - EMISSIONS CONTROL SYSTEM