Removal And Installation: Turbocharger: Removing

-- Remove the engine cover, refer to ENGINE COVER .

-- Remove the connecting tube from the air filter housing to the charge air pipe, refer to AIR FILTER HOUSING .

-- Remove the air guide pipe bolt -arrow-.

Fig 1: Identifying Air Guide Pipe Bolt

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-- Loose the hose clamp -4- and lay the air guide pipe on the cylinder head.

-- Remove the air guide hose -5- using gentle tilting motions and pivot it to the side.

-- Remove the charge air pipe.

-- Drain the coolant, refer to COOLANT, DRAINING AND FILLING .

-- Remove the bolts -arrows-.

Fig 2: Identifying Air Guide Pipe

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-- Lift clamp -2- and remove charge air hose from the connection.

-- Disconnect the connector -1- on the Oil Level thermal Sensor -G266- and unclip the bracket -2- on the subframe.

Fig 3: Identifying Oil Level Thermal Sensor G266 Wire On Subframe

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-- Remove the bolts -arrows-.

Fig 4: Drive Axle Heat Shield Bolts

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-- Remove the right drive axle heat shield.

-- Remove catalytic converters with front exhaust pipe, refer to CATALYTIC CONVERTER WITH FRONT EXHAUST PIPE .

Fig 5: Identifying Clamp And Bolts

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-- Disconnect the connectors -arrows- from the Turbocharger Recirculation Valve -N249- -1- and Charge Pressure Actuator -V465- -2-.

Fig 6: Identifying Turbocharger Recirculation Valve And Charge Pressure Actuator

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-- Loosen clip -3- and free up wire.

-- Open clips -arrows- and free up wiring harness.

Fig 7: Identifying Electrical Wiring Harness And Bolt

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-- Remove ground connection -2- from camshaft housing.

-- Remove the connector strip -1- from the Ignition Coils with Power Output Stages -- evenly and place the wiring harness aside.

-- Remove bolts -arrows- and leave coolant line -1- in installed position.

Fig 8: Identifying Coolant Line

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-- Remove the bolts -arrows- and the heat shield -1-.

Fig 9: Identifying Heat Shield

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-- Remove bolts -arrows- and remove lines -1- from turbocharger -2-.

Fig 10: Identifying Turbocharger And Lines

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-- Clean bolt -3- before loosening and lubricate the thread with hot bolt paste.

Fig 11: Identifying Support Brace

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-- Remove bolt -3- and -4- and remove support brace -1-.

-- Remove the bolt -arrow- using the Bit XZN 10 T10154 and then remove the line -1- straight off the engine.

Fig 12: Locating Bolt

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-- Remove the bolt -3-.

-- Remove the bolt -arrow-.

Fig 13: Identifying Oil Supply Line And Heat Shield

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-- Remove oil supply line -1- and the heat shield -2- from the turbocharger.

-- Remove the nuts -arrows-.

Fig 14: Identifying Turbocharger/Exhaust Manifold

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-- Remove the turbocharger/exhaust manifold upward.

Turbocharger with Mahle Charge Pressure Actuator -V465-

Fig 15: Identifying Charge Pressure Actuator Protective Boot

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-- This Charge Pressure Actuator -V465- has a protective boot.

Fig 16: Identifying Charge Pressure Actuator

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-- Remove the boot from the Charge Pressure Actuator -V465- and mount it on the new turbocharger.

Continuation for all vehicles 

-- Seal the turbocharger with the Engine Bung Set VAS 6122.