Removal and Installation

Turbocharger

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. Refer to => [ Cooling System, Draining and Filling ] Procedures

- 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. Refer to => [ Catalytic Converter ] Service and Repair

- 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.





• 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:

• 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. Refer to => [ Exhaust System, Installing ] Exhaust System, Installing.

- Fill with coolant. Refer to => [ Cooling System, Draining and Filling ] Procedures.

- Check oil level.

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

Tightening Specifications