Removal And Installation: Turbocharger

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

Special tools and workshop equipment required

Spring Type Clip Pliers VAS 5024 A
Tensioning Strap T10038

CAUTION:

If mechanical damage is found on the exhaust turbocharger, for example, a destroyed compression wheel, it is not enough to just replace the turbocharger. Perform the following steps to prevent subsequent damage.

Check the air filter housing, the air filter element and the intake hoses for contamination.
Check the entire charge air circuit and cooler for contamination.

If contaminants are found in the charge air circuit, the circuit must be cleaned and the cooler replaced, as necessary.

Removing

-- Remove the engine cover/upper air filter housing, refer to ENGINE COVER/UPPER AIR FILTER HOUSING and remove the intake hose ENGINE COVER/UPPER AIR FILTER HOUSING OVERVIEW from the turbocharger.

-- Drain the coolant. Refer to DRAINING AND FILLING .

-- Remove the right front part of the wheel housing liner.

Fig 1: Removing Right Front Part Of Wheel Housing Liners

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-- Remove the charge air hose -arrow- from the charge air cooler.

Fig 2: Removing Charge Air Hose From Charge Air Cooler

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-- Remove the bolts -arrows- and disconnect the charge air pipe.

Fig 3: Identifying Charge Air Pipe Bolts

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-- Disconnect the connectors -1 and 2- and unclip the wire.

NOTE: Ignore the -arrows-

Fig 4: Disconnecting Turbocharger Recirculating Valve N249 Electrical Harness Connector

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-- Remove the bolts -arrows- and remove the connection from the turbocharger.

-- Disconnect the heated oxygen sensor -G39- harness connector -arrow- and free up the wire.

Fig 5: Disconnecting Heated Oxygen Sensor (HO2S) G39 Harness Connector

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-- Disconnect the connectors from the ignition coils and set the wiring harness aside.

Fig 6: Disconnect Connectors Of Ignition Coils

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-- Disconnect the coolant line -arrow- from the coolant expansion tank.

Fig 7: Disconnecting Coolant Line To Coolant Expansion Tank

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-- Disconnect the coolant hoses -1 and 2-.

Fig 8: Identifying Coolant Hoses

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-- Remove the coolant pipe bolt -3-.

-- Disconnect the upper coolant hose -arrow- from the heater core.

Fig 9: Disconnecting Upper Coolant Hose From Heater Core

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-- Remove the heat shield and coolant pipe bolts -arrows-.

Fig 10: Removing Shielding Plate With Coolant Pipe

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-- Remove the crankcase ventilation line and heat shield from the turbocharger -1-.

Fig 11: Identifying Crankcase Ventilation With Heat Shield, Crankcase Ventilation From Cylinder Head Cover, Oil Supply Line & EVAP Canister Line

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-- Remove the vent tube bolts -1- and heat shield from the turbocharger.

-- Disconnect the vent tube -2- from the cylinder head cover and remove it.

-- Disconnect the vent hose -3- from the cylinder head cover and turbocharger

-- Loosen the oil supply pipe banjo bolt -4- at the turbocharger.

Fig 12: Removing Both Upper Mounting Nuts Of Front Exhaust Pipe/Turbocharger

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-- Remove the right drive axle heat shield bolts -arrows- and shield.

Fig 13: Installing Protective Cap For Drive Axle On Engine

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-- Remove both lower nuts for the front exhaust pipe to turbocharger.

Fig 14: Removing Both Upper Mounting Nuts Of Front Exhaust Pipe/Turbocharger

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-- Remove the exhaust system suspended mount bolts -arrows-.

Fig 15: Removing Bracket For Exhaust System

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-- Disconnect the exhaust system at the clamping sleeve -arrows-.

Fig 16: Disconnecting Exhaust System At Clamping Sleeve

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-- Disconnect the front exhaust pipe from turbocharger and slide it toward the rear slightly.

NOTE:

The catalytic converter is not removed and the oxygen sensor connector is not disconnected.

-- Remove the oil supply pipe and coolant supply pipe banjo bolts -arrows- from the turbocharger.

Fig 17: Identifying Oil Supply Line And Coolant Supply Line At Turbocharger

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-- Remove the oil return pipe bolts -arrows- from the turbocharger.

Fig 18: Identifying Oil Return Line

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-- Remove the bolts -1 and 2- and remove the support from the turbocharger.

Fig 19: Removing Bolts And Support For Turbocharger

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NOTE:

The following step is necessary to achieve some more room between the cylinder head and cross panel.

-- Remove the pendulum support bolts -2 and 3-.

Fig 20: Identifying Pendulum Support & Bolts

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-- Pull the engine approximately 20 mm toward the rear using the tensioning strap T10038.

Fig 21: Pulling Engine Toward Rear Using Tensioning Strap T10038

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-- Disconnect the coolant pipe -arrow-.

Fig 22: Disconnecting Coolant Pipe

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NOTE:

The fastening strip nuts do not have to be loosened.

The bolt -1- is installed only on coolant pipes with two brackets.

-- Remove the bolt -1- for the coolant pipe and remove the top nuts -arrows-.

Fig 23: Removing Bolt For Coolant Pipe And Top Nuts

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-- Remove the turbocharger/exhaust manifold upward.

Installing

CAUTION:

If mechanical damage is found on exhaust turbocharger, for example, a destroyed compression wheel, it is not enough to just replace the turbocharger. Perform the following steps to prevent subsequent damage.

Check the air filter housing, the air filter element and the intake hoses for contamination.
Check the entire charge air circuit and cooler for contamination.

If contaminants are found in the charge air circuit, the circuit must be cleaned and the cooler replaced, as necessary.

Install in reverse order of removal. Note the following:

Charge air hose installing, refer to CHARGE AIR HOSE, INSTALLING .
Always replace seals, gaskets and self-locking nuts.
Add oil to the turbocharger through the oil supply pipe connection.
The coolant return pipe must be installed together with the turbocharger. Refer to item 7.
Hose connections and charge air system hoses must be free of oil and grease before installing. Sealing ring and sealing surfaces must only be lightly oiled with connector couplings. Refer to CHARGE AIR HOSE, INSTALLING .
Secure all hose connections using hose clamps appropriate for the model type.
After installing the turbocharger, let the engine idle for approximately 1 minute to ensure adequate oil supply to the turbocharger.

Component

Pendulum supports to transmission

Refer to Fig 24.

Exhaust manifold/turbocharger to cylinder head

20 ⁽¹⁾

Oil supply pipe to turbocharger

Oil return pipe to turbocharger

Coolant supply pipe to turbocharger

Support for turbocharger to cylinder block

30 ⁽²⁾

Support to turbocharger

30 ⁽²⁾

Right charge air pipe to oil pan

⁽¹⁾	always replace

⁽²⁾	Use hot bolt paste

Fig 24: Identifying Pendulum Supports & Bolts

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