Turbocharger

Turbocharger

Special tools, testers and auxiliary items required

• Spring Type Clip Pliers (VAS 5024 A)

• Tensioning Strap (T10038)


If mechanical damage is found on the exhaust turbocharger, for example, a destroyed compression wheel, it is not enough to just replace the turbocharger. Perform the following steps to prevent subsequent damage.

• Check the air filter housing, the air filter element and the intake hoses for contamination.

• Check the entire charge air circuit and cooler for contamination.

If contaminants are found in the charge air circuit, the circuit must be cleaned and the cooler replaced, as necessary.

Removing

- Remove the engine cover/upper air filter housing, refer to => [ Engine Cover/Upper Air Filter Housing ] Engine Cover/Upper Air Filter Housing and remove the intake hose => [ (Item 11) Intake Hose ] Engine Cover/Upper Air Filter Housing Overview from the turbocharger.

- Drain the coolant. Refer to => [ Draining and Filling ] Procedures.

- Remove the right front part of the wheel housing liner.






- Remove the charge air hose - arrow - from the charge air cooler.






- Remove the bolts - arrows - and disconnect the charge air pipe.






- Disconnect the connectors - 1 and 2 - and unclip the wire.






- Remove the bolts - arrows - and remove the connection from the turbocharger.

- Disconnect the heated oxygen sensor (G39) harness connector - arrow - and free up the wire.






- Disconnect the connectors from the ignition coils and set the wiring harness aside.






- Disconnect the coolant line - arrow - from the coolant expansion tank.






- Disconnect the coolant hoses - 1 and 2 -.






- Remove the coolant pipe bolt - 3 -.

- Disconnect the upper coolant hose - arrow - from the heater core.






- Remove the heat shield and coolant pipe bolts - arrows -.






- Remove the crankcase ventilation line and heat shield from the turbocharger - 1 -.






- Remove the vent tube bolts - 1 - and heat shield from the turbocharger.

- Disconnect the vent tube - 2 - from the cylinder head cover and remove it.

- Disconnect the vent hose - 3 - from the cylinder head cover and turbocharger

- Loosen the oil supply pipe banjo bolt - 4 - at the turbocharger.






- Remove the right drive axle heat shield bolts - arrows - and shield.






- Remove both lower nuts for the front exhaust pipe to turbocharger.






- Remove the exhaust system suspended mount bolts - arrows -.






- Disconnect the exhaust system at the clamping sleeve - arrows -.






- Disconnect the front exhaust pipe from turbocharger and slide it toward the rear slightly.

• The catalytic converter is not removed and the oxygen sensor connector is not disconnected.

- Remove the oil supply pipe and coolant supply pipe banjo bolts - arrows - from the turbocharger.






- Remove the oil return pipe bolts - arrows - from the turbocharger.






- Remove the bolts - 1 and 2 - and remove the support from the turbocharger.






• The following step is necessary to achieve some more room between the cylinder head and cross panel.

- Remove the pendulum support bolts - 2 and 3 -.






- Pull the engine approximately 20 mm toward the rear using the tensioning strap (T10038).






- Disconnect the coolant pipe - arrow -.






• The fastening strip nuts do not have to be loosened.

• The bolt - 1 - is installed only on coolant pipes with two brackets.

- Remove the bolt - 1 - for the coolant pipe and remove the top nuts - arrows -.






- Remove the turbocharger/exhaust manifold upward.

Installing


If mechanical damage is found on exhaust turbocharger, for example, a destroyed compression wheel, it is not enough to just replace the turbocharger. Perform the following steps to prevent subsequent damage.

• Check the air filter housing, the air filter element and the intake hoses for contamination.

• Check the entire charge air circuit and cooler for contamination.

If contaminants are found in the charge air circuit, the circuit must be cleaned and the cooler replaced, as necessary.

Install in reverse order of removal. Note the following:

• Charge air hose installing, refer to => [ Charge Air Hose, Installing ] Charge Air Hose, Installing.

• Always replace seals, gaskets and self-locking nuts.

• Add oil to the turbocharger through the oil supply pipe connection.

• The coolant return pipe => [ (Item 7) Coolant Return Pipe ] Turbocharger Component Overviews must be installed together with the turbocharger.

• Hose connections and charge air system hoses must be free of oil and grease before installing. Sealing ring and sealing surfaces must only be lightly oiled with connector couplings. Refer to => [ Charge Air Hose, Installing ] Charge Air Hose, Installing.

• Secure all hose connections using hose clamps appropriate for the model type.

• After installing the turbocharger, let the engine idle for approximately 1 minute to ensure adequate oil supply to the turbocharger.

For the correct tightening specifications, refer to => [ Turbocharger Component Overviews ] Turbocharger Component Overviews.






1 always replace

2 Use hot bolt paste.