Removing Turbocharger, Cylinder Bank 1 - 4: Notes

Information 

• The turbocharger is removed from the engine with all lines fitted. To do this, detach the lines at the connection points on the engine side and remove the turbocharger. Only disconnect the lines on the turbocharger if they are damaged or if the turbocharger has to be replaced. 
• When removing the turbocharger take note of the connection points for the lines. 
• If the lines that are screwed to the turbocharger need to be disconnected, their position must be marked before disconnecting them. During reinstallation, the lines must be tension-free and must not be bent. 

1. Loosen the intake manifold clamp at the turbocharger -2-  . Screw on a screw-type clamp. Use a side cutters or a suitable pliers to loosen a clamped one-way clamp (hose clamp). To do this, snip open the one-way clamp. The one-way clamp must not be reused.
   Fig 1: Identifying Intake Manifold On Turbocharger

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2. Pull off the hose line at the bypass valve control box. If the line is tight, carefully lever it off with a screwdriver. Then pull off the control pressure line on the turbocharger. To do this, carefully insert a small screwdriver into the metal ring and open it. Diagram shows how to open the circlip.
   Fig 2: Locating Hose Line At Bypass Valve Control Box Connections

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   Fig 3: Opening Circlip Using Tool

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3. Remove the oil extraction line. To do this, screw off the line at the oil guide housing, turbocharger and on the vent line. Counter with an open-ended wrench. -5-  Collect emerging oil.
   Fig 4: Identifying Oil Circuit For Turbocharger

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4. Disconnect the coolant return line next to the generator. To do this, remove the spring band clamp and pull off the rubber line. Then loosen the fastening screw on the holding clamp.
   Fig 5: Locating Coolant Return Line

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5. Detach the turbocharger coolant lines from the coolant hoses or coolant guide and from the holding clamps at the engine (leave attached to the turbocharger).
   Fig 6: Identifying Turbocharger Related Components (Cylinders 1 To 4 - Cooling)

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6. Release the sheet metal holder on the oil supply line. To do this, loosen the fastening nut (M6).
   Fig 7: Locating Oil Supply Line Sheet metal Holder

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   Fig 8: Identifying Oil Circuit For Turbocharger (Cylinders 1 To 4)

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   1. Hexagon nut, M6
   2. Holding clamp
   3. Screw, M6 x 12
7. Disconnect the oil supply line at the cylinder head.
   Fig 9: Locating Oil Supply Line

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8. Remove the turbocharger support. To do this, loosen the two fastening screws at the top. Then loosen the lower screw and remove the support.
   Fig 10: Locating Turbocharger Support

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9. Remove the turbocharger. To do this, loosen the three fastening screws and remove the turbocharger with the lines attached.
   Fig 11: Locating Turbocharger Fastening Screws

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