Removing Turbocharger, Cylinder Bank 5 - 8

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. Remove the right intake manifold on the turbocharger. To do this, loosen the clamp -1-  . 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

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2. Loosen and release the turbocharger vent lines at the turbocharger and engine -4-  . To do this, loosen the union nut on the oil extraction line (counter!) and the holding clamps.

   Remove the oil extraction lines at the oil guide housing and turbocharger -8-  .

   Fig 2: Identifying Oil Circuit For Turbocharger (Cylinders 5 To 8)

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3. 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 3: Identifying Turbocharger (Cylinders 5 To 8 - Cooling)

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4. Pull off the hose line at the bypass valve control box -top arrow-  . If the line is tight, carefully lever it off with a screwdriver.
   Fig 4: Locating Hose Line At Bypass Valve Control Box Connections

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5. Disconnect the oil supply line at the cylinder head. Then release the sheet metal bracket.
   Fig 5: Locating Oil Supply Line At Cylinder Head

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6. Remove the turbocharger support. To do this, loosen the screw on the turbocharger and then loosen the two fastening screws on the cylinder head. Remove the support.
   Fig 6: Locating Turbocharger Support

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7. Remove the turbocharger. To do this, loosen the three fastening screws and pull the turbocharger out sideways. The seal between the manifold and turbocharger must not be used again.
   Fig 7: Locating Turbocharger Fastening Screws

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