Removing turbocharger

Information 

The procedure for removing and installing is described for one side as an example. The procedure for the other side is practically identical.

Information 

• Open connections and lines must be closed off using suitable stoppers or caps  .

Information 

• When removing the turbocharger, take note of the connection points for the lines  .
• Mark the installation position of the lines that are screwed to the turbocharger  .
• During re-installation, the lines must be tension-free and must not be bent  .
• Bent lines must be replaced  .

Information 

Replace sealing rings, seals and O-rings.

1. Disconnect wastegate vacuum line.
   1. 1.1. Release vacuum line -1-  and pull it off.
   2. 1.2. Loosen vacuum line from the clip.
2. Remove coolant supply -1-  and return lines -2-  .
   1. 2.1. Unscrew screw -3-  on the turbocharger.
   2. 2.2. Unscrew screws -4-  on the holder.
   3. 2.3. Loosen electric line -5-  on the holder -6-  .
   4. 2.4. Loosen clamp and pull off coolant return line -2-  .
   5. 2.5. Unscrew screw -7-  and remove coolant supply line -1-  .
   6. 2.6. Collect emerging coolant with a cloth.
3. Remove heat shield on the turbocharger.
   1. 3.1. Unscrew nut -1-  .
   2. 3.2. Detach heat shield -2-  from the holder, pull it down and remove it.
4. Remove oil extraction line -1-  and oil supply line -2-  .
   1. 4.1. Unscrew screw -6-  on the turbocharger and oil pan and pull oil line -1-  off the cylinder head.
   2. 4.2. Unscrew screws -5-  on the cylinder head.
   3. 4.3. Unscrew screw -9-  on the turbocharger and remove oil line -2-  .
   4. 4.4. Soak up emerging oil with a cloth.
5. Remove turbocharger.
   1. 5.1. Loosen nuts in the sequence -9 - 1-  .
   2. 5.2. Screw off nuts and remove turbocharger.
   3. 5.3. Replace exhaust manifold seal.
      Fig 1: Exhaust Manifold/Turbocharger Screws Tightening Sequence