Removing Turbocharger On Cylinders 1 - 4

Information 

• When removing the turbocharger take note of the connection points for the lines. 
• The installation position of the lines that are screwed to the turbocharger must be marked before disconnecting them. 
• During reinstallation, the lines must be stress-free and must not be sent. 

1. Loosen intake port on the turbocharger and remove intake port.
2. Remove oil lines, coolant lines and heat shield on the turbocharger.
   Fig 1: Oil Circuit For Turbocharger, Cylinders 1 To 4 Components Location

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   Oil circuit for turbocharger, cylinders 1 to 4

   1	Vent line for turbocharger, cylinders 1 to 4; vent line to oil extraction line for turbocharger and holding clamp for vent line to collection pipe
   2	Turbocharger oil feed line for cylinders 1 to 4; turbocharger oil feed line to connection piece; turbocharger oil feed line to cylinder head
   not shown	Connection piece for check valve to turbocharger
   3	Holder
   4	Seal
   5	Oil extraction line
   6	Screw, M6 x 12; oil extraction line for turbocharger to oil guide housing and oil feed line for turbocharger holder
   7	Screw, M6 x 16

   Fig 2: Turbocharger, Cylinders 1 To 4 - Cooling Components Location

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   Turbocharger, cylinders 1 to 4 - cooling

   1	Coolant return line for turbocharger
   2	Coolant supply line for turbocharger
   3	Clamp
   4	Coolant supply hose for turbocharger
   5	Turbocharger; exhaust manifold/turbocharger module

   1. 2.1  Remove fastening screws for oil extraction line -7-  on the turbocharger.
   2. 2.2  Remove fastening screws for oil extraction line -6-  on the oil guide housing.
   3. 2.3  Remove fastening screw for holder of turbocharger vent line -1-  >

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      Fastening screw for holder

   4. 2.4  Remove fastening screw for coolant return line -1-  on the turbocharger.
   5. 2.5  Remove turbocharger heat shield.

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      Turbocharger heat shield (cylinders 5 - 8 shown here)

      1. 2.5.1  Remove the three fastening screws -A, B, C-  for the heat shield.
      2. 2.5.2  Remove heat shield by rotating downwards -D-  .
   6. 2.6  Remove fastening screw for oil feed line -2-  on the turbocharger.
      1. 2.6.1  Remove fastening screw -6-  for holder -3-  .
   7. 2.7  Remove fastening screw for coolant supply line -2-  on the turbocharger.
      1. 2.7.1  Take coolant supply line out of the clamp -3-  .
3. Pull off line from the turbocharger vacuum unit. >

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   Vacuum unit line (cylinders 5 - 8 shown here)

4. Remove the fastening screws -1 to 12-  for the turbocharger.
   Fig 3: Turbocharger Exhaust Manifold Fastening Screws Loosening Sequence

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   Fastening screws for turbocharger exhaust manifold

5. Remove turbocharger -1-  seal -2-  and tab washers -3 and 4-  .
   Fig 4: Turbocharger Exhaust Manifold, Cylinders 1 To 4 Components Location

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   Turbocharger exhaust manifold, cylinders 1 to 4

   1	Turbocharger exhaust manifold, cylinders 1  to 4
   2	Seal; install so that marking on seal is legible
   3	Lower tab washer
   4	Upper tab washer
   5	Nut M8; turbocharger exhaust manifold to cylinder head; replace