Turbocharger, Removing And Installing: Removing

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

-- Remove the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

-- Open the clamps -1 and 2- and remove the connecting pipe -3-.

Fig 1: Identifying Connecting Pipe And Clamps

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-- Remove the bolt -arrow- from the oil separator.

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-- Remove the lines -1- from the oil separator.

-- Remove the air duct pipe bolt -1-.

Fig 2: Identifying Air Guide Pipe

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-- Loosen the hose clamp -2- and remove the air duct pipe from the turbocharger.

-- Remove the air duct pipe -4- with the lines for the crankcase ventilation -3- from the turbocharger.

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

-- Remove the right front wheel housing liner.

-- Remove the bolts -arrows-.

Fig 3: Identifying Air Guide Pipe

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

-- Disconnect the connector -1- for the Oil Level Thermal Sensor -G266-. Unclip the bracket -2- from the subframe.

Fig 4: Identifying Oil Level Thermal Sensor G266 Wire On Subframe

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-- Remove the bolts -arrows-.

Fig 5: Drive Axle Heat Sheild

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-- Remove the right drive axle heat shield.

-- Remove the catalytic converter with the front exhaust pipe. Refer to CATALYTIC CONVERTER, REMOVING AND INSTALLING .

-- If equipped, remove the ground cable -arrows-.

Fig 6: Identifying Ground Wire

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-- If equipped, remove the ground wire -2- from the camshaft housing.

Fig 7: Identifying Electrical Wiring Harness And Bolt

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

-- Open the clips -arrows- and pivot the wiring harness to the side.

-- Remove the bolts -arrows-.

Fig 8: Identifying Coolant Line

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-- Remove all coolant hoses from the coolant pipe and remove the coolant pipe.

NOTE:

Clearance is needed to remove the turbocharger.

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

Fig 9: Identifying Heat Shield

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-- Open the clamp -arrow- and remove the hose -1- as far as possible from the coolant pipe.

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-- Remove the bolts -arrows-. Remove the heat shield -1- and support -2-.

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-- Remove the lower nuts -1 and 2-.

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

Fig 10: Identifying Turbocharger And Lines

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-- Remove the bolts -arrows-. Remove the coolant support -1- and oil return pipe -2- from the cylinder block.

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-- Remove the bolt for the oil supply line -3- and remove the oil supply line from the cylinder block.

-- Remove the nuts -arrows- for the turbocharger -1-

Fig 11: Identifying Turbocharger/Exhaust Manifold

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-- Remove the turbocharger slightly from the stud bolts and disconnect the connectors -arrows- from the Turbocharger Recirculation Valve -- -1- and Charge Air Pressure Actuator -- -2-.

Fig 12: Identifying Turbocharger Recirculation Valve And Charge Pressure Actuator

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

-- Remove the turbocharger/exhaust manifold upward.

Turbocharger with Mahle Charge Air Pressure Actuator -V465-

Fig 13: Identifying Charge Pressure Actuator Protective Boot

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

Fig 14: Identifying Charge Pressure Actuator

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

Continuation for All Vehicles

-- Seal the turbocharger with the Engine Bung Set:VAS6122 .