Removing Turbocharger

Information 

The procedure for removing and installing is described for one side as an example. The procedure for the other side is almost identical.

Information 

• Open connections and lines must be closed off using suitable stoppers or caps. 

1. Disconnect vacuum hose from the turbocharger vacuum unit.
2. Release and disconnect electric plug connection -1-  .

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   Electric plug connection for turbocharger shut-off valve

3. Disconnect oil supply line -1-  .

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   Oil line on right turbocharger

   1. 3.1  Unscrew screw for oil supply line -2-  and pull off oil supply line -1-  .
   2. 3.2  Catch emerging oil using suitable aids.
4. Disconnect coolant lines -1-  and -2-  on the turbocharger.

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   Coolant lines on right turbocharger

   1. 4.1  Unscrew and remove screws -3-  .
   2. 4.2  Disconnect coolant return line -1-  .
   3. 4.3  Disconnect coolant supply line -2-  .
   4. 4.4  Catch emerging coolant using suitable aids.
5. Loosen V-band clamp -1-  .

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   V-band clamp on turbocharger/catalytic converter flange

   1. 5.1  Loosen screw -2-  and release V-band clamp -1-  .
   2. 5.2  Carefully loosen V-band clamp -1-  from the turbocharger/catalytic converter flange using a hammer and wedge.
6. Loosen turbocharger -1-  .

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   Mounting for right turbocharger

   1. 6.1  Unscrew nuts on studs -2-  and unscrew studs -3-  .
   2. 6.2  Unscrew nuts on turbocharger -4-  .

   Information 

   When removing the turbocharger, the oil return line will be damaged and must always be replaced following removal.

7. Remove turbocharger -1-  .

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   Active carbon filter line on turbocharger

   1. 7.1  Lift up turbocharger -1-  until screw for active carbon filter line -2-  is accessible.
   2. 7.2  Unscrew screw for active carbon filter line -2-  and pull off active carbon filter line -3-  .
   3. 7.3  Remove turbocharger -1-  with oil return line.
8. Replace oil return line -1-  for turbocharger.

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   Oil return line for turbocharger

   1. 8.1  Remove pin -2-  from the turbocharger.
   2. 8.2 Secure new  oil return line -1-  with a new  pin -2-  on the turbocharger.