Removing Turbocharger On Cylinders 1 - 3

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. Loosen intake pipe on the turbocharger and remove intake pipe.
2. Disconnect pressure pipe at the turbocharger.
3. Remove heat protection on the turbocharger.
   1. 3.1. Unscrew nut -7 -  and remove heat protection -4-  .
      Fig 1: Identifying Exhaust Manifold/Turbocharger Components (Cylinders 1-3)

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4. Loosen ATF line -1-  on the cylinder head.
   1. 4.1. Unscrew screws -2-  .
   2. 4.2. Unscrew screw -3-  on the oil cooler -4-  .
   3. 4.3. Guide out ATF line.
      Fig 2: Removing ATF Line

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5. Pull off control line -1-  at the vacuum unit.
   Fig 3: Identifying Vacuum Unit Control Line

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6. Remove turbocharger coolant lines -1-  and -2-  .
   1. 6.1. Unscrew fastening screws -4-  .
   2. 6.2. Disconnect coolant line -2-  at the coolant distributor.
   3. 6.3. Loosen clamp and pull off coolant line -1-  .
   4. 6.4. Collect emerging coolant.
   5. 6.5. Close off openings using suitable stoppers.
      Fig 4: Identifying Turbocharger Cooling Lines (Cylinders 1-3)

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7. Remove turbocharger oil lines -1-  and -2-  .
   1. 7.1. Unscrew screws -5-  and pull off oil line -2-  .
   2. 7.2. Unscrew screw -6-  and pull off oil line -1-  at the oil pan.
   3. 7.3. Collect emerging oil.
   4. 7.4. Close off openings using suitable stoppers.
      Fig 5: Identifying Turbocharger Oil Circuit (Cylinders 1-3)

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8. Remove turbocharger.
   1. 8.1. Unscrew nuts in the sequence -9 - 1-  .
   2. 8.2. Remove turbocharger and seal.
      Fig 6: Identifying Exhaust Manifold/Turbocharger Nut Loosening Sequence

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