Remove turbocharger

WARNING: Hot surfaces .
Risk of burning!

Perform all work only on components that have cooled down.

WARNING: Working on 12 V electrical system .
Risk of short circuits! Risk of fire!

Make sure that there is no charger connected to the jump start terminal in the engine compartment.
Detach battery ground lead from battery.
For auxiliary batteries: Detach battery minus cables from all auxiliary batteries.

NOTE: RISK OF DAMAGE
Electrostatic discharge .
Damage to or destruction of electrical components .

Leave the electrical components in their original packaging until they are being installed. Only use the original packaging for returning the product. Always package removed components straight away.
Read and comply with user information on using the associated special tool 12 7 060.
Only tap the housings of electrical components. Do not tap pins or multi-pin connectors directly.
Wear electrically conductive clothing and antistatic shoes (with ESD symbol).
For additional information see: NOTES ON ESD PROTECTION (ELECTRO STATIC DISCHARGE) .

NOTE: RISK OF DAMAGE
Damage to battery terminal, the safety battery terminal or the intelligent battery sensor (IBS) .
Damaged battery terminals can lead to malfunctions or vehicle electrical system faults .

Detach battery terminal from battery pole by carefully shifting to and fro. Do not pry off using a tool.

NOTE: TECHNICAL INFORMATION
For turbocharger damage: Check the pressure pipes, charge air cooler and intake plenum for foreign matter, damage and correct functionality.
If the oil return line is exchanged, then the connecting pipe to the oil sump must ALWAYS be cleaned, as the connecting pipe can coke.

NOTE: TECHNICAL INFORMATION
Collect and dispose of emerging fluids. Observe country-specific waste disposal regulations.

NOTE: TECHNICAL INFORMATION
If the turbocharger is damaged, it is imperative to observe the additional information.
For additional information see: 11 65 020 Turbocharger damage due to plugged oil supply lines

Preliminary work

Refer to BRINGING FRONT COMPARTMENT LID IN THE SERVICE POSITION .
Refer to REMOVING THE SEAL FOR THE HOOD REAR .
Refer to REMOVING THE ACOUSTIC COVER .
Refer to REMOVING ACOUSTIC COVER AT REAR .
Refer to REMOVING SEAL FOR FRONT HOOD .
Refer to IF INSTALLED: PARTIALLY REMOVING THE TOP RIGHT AND LEFT COVER IN THE ENGINE COMPARTMENT .
Refer to REMOVING THE COVER FOR THE CENTER ENGINE COMPARTMENT .
Refer to REMOVING THE LEFT AND RIGHT FRONT-END STRUT .
Refer to REMOVING UPPER CROSS CONNECTION .
Refer to REMOVING THE REAR TOP CROSS CONNECTION .
Refer to REMOVING THE FAN COWL .
Refer to REMOVING INTAKE SILENCER HOUSING .
Refer to REMOVING ENGINE VENTILATION LINE .
Refer to REMOVING CLEAN AIR PIPE .
Refer to REMOVING CHARGE AIR LINE .
Refer to REMOVING THE ADAPTER FOR ENGINE VENTILATION LINE WITH HEATING ELEMENT ON TURBOCHARGER .
Refer to PARTIALLY RELEASING THE HOLDER OF THE POSITIVE BATTERY CABLE .
Refer to REMOVING THE OXYGEN SENSOR MONITOR .
Refer to REMOVING THE LAMBDA OXYGEN SENSOR .
Refer to REMOVING THE FRONT UNDERBODY PROTECTION .
Refer to REMOVING THE CENTER UNDERBODY PROTECTION .
Refer to REMOVING THRUST FIELD .
Refer to REMOVING REAR UNDERBODY PROTECTION .
Refer to REMOVING THE COVER OF THE STEERING ASSEMBLY .
Refer to REMOVING THE OIL RETURN LINE FOR THE TURBOCHARGER .
Refer to REMOVING THE CONNECTING SUPPORT FROM THE TUNNEL .
Refer to REMOVING COMPLETE EXHAUST SYSTEM .
Refer to REMOVING CATALYTIC CONVERTER .
Refer to DRAINING THE COOLANT FROM THE HIGH-TEMPERATURE COOLING SYSTEM .
Refer to CONNECTING THE COOLANT LINE TO THE HIGH-TEMPERATURE COOLANT RADIATOR .

Turbocharger

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CAUTION: Heavy component .
Heavy components can lead to injury or damage .

Remove and install heavy components with the aid of another person/other persons.

NOTE: RISK OF DAMAGE
Damage of the electric wastegate valve controller .
Excessive force when removing and installing a jammed turbocharger may damage the electric wastegate valve controller .

Do not pull on the electrical wastegate valve controller or on the coupling rod.
Apply force only at the turbine housing and exhaust manifold.
Do not pull on the compressor housing.

NOTE: TECHNICAL INFORMATION
Do not damage the thermal compensating elements. Disassembly and installation including intermediate storage of the turbocharger is only permitted with mounted special tool 2 466 919.

NOTE: TECHNICAL INFORMATION
Collect and dispose of emerging fluids. Observe country-specific waste disposal regulations.

Loosen screws (1).
Loosen screw (2) .
Feed out and remove the heat shield (3) .

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Loosen screws (1) .
Feed out and remove the heat shield (2) .

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Unlock and release the coolant return line (1) to the coolant pump (2) for the turbocharger.
Catch and dispose of leakage coolant.

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Release the screw (1) at the coolant return line (2) .

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Loosen screw (1).
Feed out the oil feed line (2) for the turbocharger and set it aside.
Catch and dispose of emerging motor oil.

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Loosen screws (1) and (2) .
Feed the coolant feed line for the turbocharger (3) out of the crankcase and place aside.
Catch and dispose of leakage coolant.

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Loosen screws (1) and (2) .
Feed out the support (3) and remove it.

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Ready the special tool 2 446 919 and the special tool 2 466 467 .

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Install the special tool 2 446 919 on the turbocharger and secure it with the bolt (1) .
Make sure that the special tool 2 446 919 is flush with the turbocharger in the marked area .

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Secure the special tool 2 446 919 by turning the clamping lever (1) in the direction of the arrow .
NOTE: The clamping lever that is shown in the graphic is already in its end position.

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Position the holder (1) and fasten it with the bolt (2) .
NOTE: The holder is used for the final mounting of the special tool 2 446 919.

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Tighten the nut (1) hand-tight.
Tighten the nut (2) hand-tight.
Make sure that the special tool 2 466 467 is correctly positioned on the turbocharger (3) .

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Tighten the nut (1) hand-tight.
Tighten the nut (2) hand-tight.
Make sure that the special tool 2 466 467 is correctly positioned on the turbocharger (3) .

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Tighten nut (1) with standard tools (2) .

TIGHTENING TORQUE SPECIFICATION

Special tool 2 466 467 on special tool 2 446 919
M8	tightening torque	5 Nm

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Tighten nut (1) with standard tools (2) .

TIGHTENING TORQUE SPECIFICATION

Special tool 2 466 467 on special tool 2 446 919
M8	tightening torque	5 Nm

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Tighten nut (1) with standard tools (2) .

TIGHTENING TORQUE SPECIFICATION

Special tool 2 466 467 on special tool 2 446 919
M8	tightening torque	5 Nm

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Tighten nut (1) with standard tools (2) .

TIGHTENING TORQUE SPECIFICATION

Special tool 2 466 467 on special tool 2 446 919
M8	tightening torque	5 Nm

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NOTE: TECHNICAL INFORMATION
Exhaust manifold/turbocharger is not bolted to the underside, but clamped instead. When removing/replacing the exhaust manifold/turbocharger, the trim strip remains screwed on.

Release the nut in the sequence (7) to (1) .
Secure turbocharger against falling down.

Fig 1: Turbocharger Screws Loosening Sequence
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Guide out and remove the sliding frame (1) .

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CAUTION:
Heavy component .
Heavy components can lead to injury or damage .
- Remove and install heavy components with the aid of another person/other persons.
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Carefully guide out and remove the turbocharger (1) .
Thermal compensating element of the turbocharger (1) or the exhaust manifold should not be bent or deformed.
Feed out and remove the seal (1) in the marked area .

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