Turbocharger, Removing and Installing

Turbocharger, Removing And Installing

Special tools, testers and auxiliary items required







- Spring-type clip pliers VAS 5024 A

Removing







- Remove engine cover - arrows - .

CAUTION: Cover cap of expansion tank with rag and open carefully, as hot steam or hot coolant may escape when opening.

- Open cap of coolant expansion tank.
- Drain engine coolant







- Remove heat shield - arrows - .







- Remove crankcase ventilation line from turbocharger - 1 -.
- Pull off crankcase ventilation line from the cylinder head cover - 2 - and remove it.
- Disconnect EVAP line to turbocharger from cylinder head cover - 3 - .
- Remove oil supply line from turbocharger - 4 - .
- Remove catalytic converter







- Remove coolant supply line to turbocharger - arrow - .







- For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.







- Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation.
- Remove quick-release fasteners - 3 - and remove rear noise insulation, if installed.







- Remove air duct hose - 1 - to turbocharger at bottom right.
- Remove air duct hose to charge air cooler at lock carrier - 2 -







- Disconnect connector - 1 and 2 - and free up cable.







- Remove oil supply line for turbocharger at cylinder block - 1 - .
- Remove bolt - 2 - of support for turbocharger.







- Remove oil supply line for turbocharger - arrows - .







- Disconnect oil return line - arrows - from turbocharger.







- Loosen bolt - 1 - of support for turbocharger by 2 turns.







- Disconnect coolant pipe - arrow - .







- Remove coolant pipe - 1 - , if present, from cylinder head.

NOTE: Nuts on bottom of fastening strip do not need to be opened

- Remove upper nuts - arrows - .
- Remove turbocharger/exhaust manifold upward.

Installing

Installation is in reverse order of removal, note the following:

NOTE:
- Always replace seals, gaskets and self-locking nuts.
- Add oil to turbocharger through oil feed line connecting piece.
- Hose connections and charge air system hoses must be free of oil and grease before installing.
- Secure all hose connections using hose clamps appropriate for the model type.

- Install exhaust system and align it free of tension.
- Fill with coolant.
- Check oil level

NOTE: After installing turbocharger, let engine idle for approx. 1 minute without increasing engine speed. This ensures adequate oil supply to the turbocharger.

Torque specifications

Exhaust manifold/turbocharger to cylinder head 21 Nm 1) 2)
Oil supply line to exhaust turbocharger 30 Nm
Bracket for oil supply line to exhaust manifold 20 Nm 2)
Bracket for turbocharger to cylinder block 30 Nm 2)
Turbocharger bracket to turbocharger 30 Nm 2)
Oil return line to turbocharger 9 Nm

1) Replace bolt or nut
2) Coat studs of exhaust manifold and threads of oxygen sensor with hot bolt paste