Removing Turbocharger

WARNING: This page is about a different variant/trim than selected.

CAUTION: Hot components

Risk of burns
→ Let hot components cool down.

→ Wear personal protective gear.

WARNING: Hot fluid

Danger of scalding
→ Let the fluid cool down.

→ Wear personal protective gear.

NOTE: NOTIFICATION
Mixing fluids

Risk of damage to components
→ Close off all openings immediately after exposing them (with adhesive tape, suitable stoppers).

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

Replace O-rings on the cooling system.
Clean plug connection and coolant hoses before assembly.
Remove stoppers before fitting the coolant lines and hoses.

Information

O-rings must always be replaced.
O-rings must be coated lightly with Kluber Syntheso Glep.

Remove pressure hose -1- from turbocharger.
Loosen screw-type clamps -2- .

Pull off pressure hose -1- .

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Pressure hose for turbocharger
Right side only: Disconnect crankcase ventilation line -1- from the intake manifold -2- .
Disconnect connection -Arrows- and remove.

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Crankcase ventilation line intake port
Remove intake pipe -1- at the turbocharger.
Undo -2- V-band clip screw.

Loosen screw-type clamp -3- .

Remove -1- intake port.

Replace V-band clip for installation.

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Intake pipe on turbocharger
Disconnect vent line -1- .
Unscrew screw -2- .

Disconnect vent line -1- .

Collect emerging oil.

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Turbocharger vent line
Disconnect oil line (intake side) -1- .
Unscrew screw -2- .

Release support -3- by unscrewing screw -4- .

Remove oil line -1- .

Collect emerging oil.

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Oil line (intake side)
Disconnect tank vent line -1- .
Unscrew screw -2- .

Remove tank ventilation line -1- by moving it upwards.

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Turbocharger tank vent line
Disconnect coolant lines -1- and -2- .
Unscrew screw -3- .

Loosen holder -4- .

Pull off coolant lines -1- and -2- .

Collect emerging coolant.

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Coolant lines for turbocharger
Disconnect oil line (pressure side) -1- .
Unscrew screw -2- .

Remove oil line -1- .

Collect emerging oil.

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Oil line (pressure side)
Release cable plug -1- on electronic adjuster and remove it.

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Cable plugs for electronic adjuster
Remove V-band clip -1- on the catalytic converter.
Unscrew screw -2- .

Remove V-band clip -1- .

Replace V-band clip for installation.

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V-band clip for catalytic converter/turbocharger
Disconnect turbocharger from the exhaust manifold.
Unscrew nuts -1- .

Remove turbocharger by pulling it downwards.

Replace seal -2- .

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Turbocharger on exhaust manifold
Loosen catalytic converter -1- .
Unscrew screws -2- on the holder.

Undo nuts -3- on the clamping sleeve.

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Catalytic converter

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

Replace O-rings on the cooling system.
Clean plug connection and coolant hoses before assembly.
Remove stoppers before fitting the coolant lines and hoses.

Information

O-rings must always be replaced.
O-rings must be coated lightly with Kluber Syntheso Glep.

Replace seal -1- at the connection point of the turbocharger and the catalytic converter.

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Turbocharger/catalytic converter seal
Secure the catalytic converter -1- .
Position the catalytic converter and clamping sleeve in installation position.

Tighten screws -2- on the support.

Tightening torque: > Tightening torque 23 Nm (17 ftlb.) +/- 10 %

Tighten nuts -3- on the clamping sleeve.

Tightening torque: > Tightening torque 30 Nm (22 ftlb.) +/- 10 %

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Catalytic converter
Fix turbocharger to the exhaust manifold.
Insert new seal -2- .

Coat studs with MicroGLEIT LP 475 .

Position turbocharger in installation position.

Tighten new nuts -1- .

Tightening torque: > Tightening torque 25 Nm (19 ftlb.)

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Turbocharger on exhaust manifold
Attach turbocharger to the catalytic converter.
Fit new V-band clip -1- on the catalytic converter.

Tighten screw -2- .

Tightening torque: > Tightening torque 20 Nm (15 ftlb.)

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V-band clip for catalytic converter/turbocharger
Connect cable plug -1- to electronic adjuster.

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Cable plugs for electronic adjuster
Secure oil line (pressure side)-1- .
Replace O-rings.

Tighten screw -2- .

Tightening torque: > Tightening torque 10 Nm (7.5 ftlb.)

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Oil line (pressure side)
Secure coolant lines -1- and -2- .
Replace O-rings.

Secure holder -4- .

Tighten screw -3- .

Tightening torque: > Tightening torque 10 Nm (7.5 ftlb.)

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Coolant lines for turbocharger
Secure tank vent line -1- .
Replace O-rings.

Tighten screw -2- .

Tightening torque: > Tightening torque 10 Nm (7.5 ftlb.)

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Turbocharger tank vent line
Disconnect oil line (intake side) -1- .
Replace O-rings.

Insert oil line -1- into the turbocharger.

Fit screws -2- .

Secure support -3- , to do this, fit a screw -4- .

Tighten screw -2- .

Tightening torque: > Tightening torque 10 Nm (7.5 ftlb.)

Tighten screw -4- .

Tightening torque: > Tightening torque 10 Nm (7.5 ftlb.)

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Oil line (intake side)
Secure vent line -1- .
Replace O-rings.

Tighten screw -2- .

Tightening torque: > Tightening torque 10 Nm (7.5 ftlb.)

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Turbocharger vent line
Fit intake line -1- to turbocharger.
Replace O-ring.

Fit the new V-band clip.

Tighten screw -2- .

Tightening torque: > Tightening torque 5.5 Nm (4 ftlb.) +/- 0.2 Nm (0.1 ftlb.)

Tighten new screw-type clamp -3- .

Tightening torque: > Tightening torque 5.5 Nm (4 ftlb.) +/- 0.2 Nm (0.1 ftlb.)

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Intake pipe on turbocharger
Fit pressure hose -1- on turbocharger.
Tighten screw-type clamps -2- .

Tightening torque: > Tightening torque 5.5 Nm (4 ftlb.) +/- 0.2 Nm (0.1 ftlb.)

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Pressure hose for turbocharger