Removing and installing oil pump for turbocharger: Removal

Fig 1: Exploded View Of Turbocharger Oil Pump

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1. Raise the vehicle at the prescribed jacking points.
2. Disconnect battery.
3. Open engine compartment lid.
4. Remove rear spoiler. Serv. No.: 63 55 19
5. Remove bumper with shield.
6. Remove lateral shields.
   Fig 2: Removing Lateral Shields

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7. Loosen fastening nuts.
   Fig 3: Identifying Fastening Nuts

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8. Loosen fastening nuts on the turbocharger. Remove the shield.
   Fig 4: Loosening Fastening Nuts On Turbocharger

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9. Detach restraining straps. Undo the two restraining straps on the rear muffler. Loosen the two -hexagon socket screws-  for this purpose.
   Fig 5: Locating Restraining Straps On Rear Muffler

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   CAUTION: Falling rear muffler! The rear muffler is loose after the restraining straps are removed. The rear muffler should be held by a second person or supported with a transmission jack.
10. Push restraining straps out of the holder. Press the restraining strap into the recesses on the engine carrier using a screwdriver and move outwards.-View from engine side- 
11. Remove rear muffler. Two persons can now remove the rear muffler.
12. Undo fastening screw M 6 x 34 on the air cleaner housing.
    Fig 6: Locating Fastening Screw On Air Cleaner Housing

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13. Undo hose clamp between the air cleaner housing and intake manifold.
14. Tilt the complete air cleaner housing 90° upward and then remove from the engine compartment.
    Fig 7: Tilting Complete Air Cleaner Housing 90° Upward

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15. Pull of the connecting hoses between the charge air coolers and the pressure pipe. Unclip the locking clips using a screwdriver and pull off the hose. Then clip the locking clips in again.
16. In order to remove the pressure pipe, loosen the hose clamps and hexagon-head bolts. Pull off the electrical plug.
    Fig 8: Removing Pressure Pipe Bolts

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17. Disconnect oxygen sensor plug on the rear closing panel.
    Fig 9: Disconnecting Oxygen Sensor Plug On Rear Closing Panel

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18. Disconnect oxygen sensor plug.
    Fig 10: Disconnecting Oxygen Sensor Plug

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19. Undo the three fastening screws of the belt pulley on the hydraulic system pump by approx. 1/2 turn.
20. Relieve drive belt. To do this turn the tensioning roller clockwise, hold and simultaneously remove the drive belt.
    Fig 11: Relieving Drive Belt Tension

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21. Remove pulley from the hydraulic pump.
22. Remove generator.
    Fig 12: Removing Generator

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23. Disconnect the hydraulic lines with plug-in coupling on the expansion tank.
    NOTE:

    • Wear protective gloves!
    • Collect emerging Pentosin!
    • Protect the line against dirt and scratches with a cap!
    • If hoses come into contact with Pentosin, clean them thoroughly without delay!
24. Insert tool between lines and the red unlocking ring and unlock by pulling black line to the right and simultaneously pressing the tool against the red unlocking ring.
    Fig 13: Inserting Tool Between Lines And Red Unlocking Ring

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25. Unscrew two fastening screws (M8 x 25) with hexagon socket head bolts on the tank.
26. Unscrew three M8 screws and one M6 screw between the hydraulic pump and the console. Pull the expansion tank with hydraulic pump out of the bracket and suspend on the side.
    Fig 14: Identifying Screws Between Hydraulic Pump And Console

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27. Detach the air conditioning compressor and remove the bracket. To do this, disconnect the electrical plug connection, remove the compressor and set it down with the hoses connected.
28. Disconnect the fuel lines on the fuel cooler. Make sure to counter with a wrench when doing this.
    Fig 15: Disconnecting Fuel Lines On Fuel Cooler

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29. Loosen hose clamps on the intake distributor and pivot the throttle body upward. Undo the fastening screws and remove the throttle body.
    Fig 16: Locating Throttle Body Fastening Screws

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30. Unscrew closure cap of coolant expansion tank. Undo coolant drain plugs on right and left and drain the coolant.
    Fig 17: Removing Closure Cap Of Coolant Expansion Tank

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31. Equip drain plugs with new sealing rings.

    Tightening torque: 10 to 15 Nm (7.5 to 11.0 ftlb.). 

32. Pull off the right and left coolant hoses. Lever off the locking clip for this purpose.
    Fig 18: Removing Coolant Hoses Locking Clip

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33. Refit the locking clip on the coolant neck.
    Fig 19: Installing Locking Clip On Coolant Neck

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34. Remove bracket for generator. Undo hexagon-head bolts.
    Fig 20: Removing Bracket For Generator

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35. Loosen coolant neck.
    Fig 21: Loosening Coolant Neck

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36. Undo coolant hoses over the coolant pump.
    Fig 22: Removing Coolant Hoses From Coolant Pump

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    NOTE:

    • Tip for easier assembly!
    • The coolant hoses are easier to remove when the complete bracket is removed later.
37. Loosen the stabilizer at top and swivel it downward.
    Fig 23: Loosening Stabilizer Bar Mount At Top

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    NOTE: When swivelling, make sure not to damage the bellows on the lower joint!
38. Support the engine-transmission unit. Fasten special tool (retaining device) 9624/1 on the take-up points of the stabilizer mounts. The pressure disc must rest on the crankcase or crash support.
    Fig 24: Supporting Engine-Transmission Unit

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39. Separate engine carrier from the engine mounts (wrench size 18).
40. Loosen engine carrier on the bracket.
    Fig 25: Loosening Engine Carrier On Bracket

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41. Secure the bracket with a shorter auxiliary screw (M10 x 55).
    Fig 26: Securing Bracket With Shorter Auxiliary Screw

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42. Detach the oil supply line from the bracket (right-hand side).
    Fig 27: Removing Oil Supply Line From Bracket (Right-Hand Side)

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43. Detach the oil supply lines from the bracket (left-hand side).
    Fig 28: Removing Oil Supply Lines From Bracket (Left-Hand Side)

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44. Remove auxiliary screw again.
    Fig 29: Removing Auxiliary Screw

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45. Remove complete bracket. Simultaneously pull off coolant hoses.
46. Undo oil pump fastening screws and remove the cover.
    Fig 30: Locating Oil Pump Fastening Screws

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47. Check oil pump cover and contact surface of the oil pump gears in the bracket for signs of seizing or excessive wear. The entire bracket must be replaced if necessary. The bracket, oil pump gear and oil pump cover are matched.