Removal and Replacement
Turbocharger
Special tools, testers and auxiliary items required
- Hose clamp pliers VAS 6340
Caution: If mechanical damage is found on the exhaust turbocharger, e.g. a destroyed compressor wheel, it is not enough to just replace the turbocharger. Perform the following steps to prevent future damage.
- Check the air filter housing, the air filter insert and the intake hose for contamination.
- Check entire air charge circuit and cooler for contamination.
- If contaminants are found in air charge circuit, circuit must be cleaned and cooler replaced if necessary.
- Disconnect the hose -arrow- leading to the charge pressure regulation vacuum diaphragm.
- Disconnect the hose -4- leading to the air filter housing.
- Disconnect the tube leading to the crankcase ventilation -5- on the air guide pipe.
- Loosen the spring type clamp on the turbo charger.
- Free up the vacuum hoses.
- Remove the bolts -1- and -2- and remove the air guide tube -3-.
- Remove the oil supply line on the oil filter bracket -arrow- and also on the coolant pipe.
- Remove the air guide tube on the right longitudinal member -arrows-.
- Remove the center and right noise insulation.
- Remove heat shield for right axle shaft -arrows-.
- Unbolt the right axle shaft from the transmission flange.
- Unscrew the exhaust system bracket on the subframe -arrows-.
- Remove the front exhaust pipe.
- Disconnect the pendulum supports on the subframe -arrows A-.
- Remove the air guide hose -4-.
- Unscrew bolts -2- and -3- and remove turbocharger bracket.
- Remove oil return line -1- at cylinder block.
- Disconnect the Vane Position Sensor connector from the turbocharger.
- Remove the connecting pipe for the exhaust gas recirculation -arrows-.
- Disconnect the oil supply line on the turbo charger and on the exhaust manifold -arrows-.
- Remove the heat shield from the exhaust manifold -arrows-.
- Remove the nuts -arrows-.
- Remove the washers.
- Remove the exhaust manifold/turbo charger to the rear.
- Installing is performed in reverse order. When doing this note the following.
- Seals, sealing rings and self-locking nuts must always be replaced.
- Pay attention to the installation position of the seal for the exhaust manifold/turbocharger.
- Add oil to the turbocharger through oil feed line connecting piece.
- Hose connections and charge air system hoses must be free of oil and grease before installing. Only on connector couplings, the sealing surfaces must be lightly oiled.
- Charge air system must be properly sealed.
- All hose connections for charge air system are secured by spring type clamps or by connector couplings.
- Install the exhaust system and align it fee of tension.
- Install the right axle shaft.
- Check engine 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
Component Nm
Exhaust manifold/turbocharger to cylinder head 25 *
Heat shield to exhaust manifold/turbocharger 20 *
Connecting pipe for exhaust gas recirculation 22 *
Oil supply line to turbocharger 22
Bracket for oil supply line to exhaust manifold 22 *
Bracket for turbocharger to cylinder block 40
Bracket for to cylinder block 40
Turbocharger bracket to turbocharger 20
Oil return line to cylinder block 30
Oil supply line to oil filter bracket 25
Pendulum supports to subframe 25