Turbocharger, Removing And Installing: Removing

NOTE:

During installation, all heat shield boots must be installed at the same location.

CAUTION:

Prevent the risk of malfunction caused by contamination.

Refer to GUIDELINES FOR CLEAN WORKING CONDITIONS

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

-- Remove the air duct pipe between charge air cooler and turbocharger. Refer to AIR DUCT PIPE BETWEEN CHARGE AIR COOLER AND TURBOCHARGER, REMOVING AND INSTALLING .

-- Remove the turbocharger connection. Refer to TURBOCHARGER CONNECTIONS, REMOVING AND INSTALLING .

-- Remove the Charge Air Pressure Control Module -GX34-. Refer to Charge Air Pressure Control Module -GX34-, REMOVING AND INSTALLING .

-- Remove the Secondary Air Injection Pump Motor -V101- with the bracket. Refer to Secondary Air Injection Pump Motor -V101-, REMOVING AND INSTALLING .

-- Press the release button -b- from the hose for the crankcase ventilation -1- and remove the hose.

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-- Remove the bolts -a- and remove the hose from the turbocharger -2-.

-- Remove the upper heat shield over the turbocharger and the catalytic converter.

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-- To do so remove the bolts -d and e- and remove the heat shield -5-.

NOTE:

The right bolt -d- seen from the direction of travel is not installed on all vehicles

-- Position the Shop Crane - Drip Tray :VAS6208 below to collect the fluid.

-- Remove the drive axle heat shield. Refer to DRIVE AXLE HEAT SHIELD, REMOVING AND INSTALLING .

-- Remove the bolts for the coolant pipes -b and c-.

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-- Disconnect the coolant hoses to the coolant pipes using the Hose Clamps - Up To 25 mm :3094 .

-- Loosen the clamps -arrows- and remove the coolant hoses.

-- Mark the installation position of the screw-type clamp -2- between the turbocharger and the catalytic converter. Refer to Fig 1.

Fig 1: Positioning the Clamp

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Fig 2: Identifying Catalytic Converter Nuts And Bolts

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-- Loosen and remove the screw-type clamp -2-.

-- Remove the bolt -1-.

-- Loosen the nuts -arrows-.

-- Loosen the remaining threaded connections from the catalytic converter on the bracket and on the engine. Refer to OVERVIEW - EMISSIONS CONTROL SYSTEM .

-- Push the catalytic converter to the right.

AWD Vehicles:

-- Remove the right drive axle from the transmission and tie it up. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

-- Remove the bolts -1 and 3-.

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-- Remove the bracket for the bevel box -2-.

Continuation for All Vehicles:

-- Place a cloth to collect the oil under the oil lines.

-- Remove the bolts -f-.

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-- Remove the oil supply line -3-.

-- Remove the nuts -arrows-.

Fig 3: Identifying Turbocharger Nuts

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-- Pull the turbocharger and the oil return line evenly toward the rear.

-- Remove the turbocharger together with the coolant pipes and the oil return line from the engine.

-- Remove the turbocharger together with the coolant pipes and the oil return line upward.