Turbocharger

Turbocharger

Special tools, testers and auxiliary items required

• Spring Type Clip Pliers (VAS 5024 A)

• Tensioning Strap (T10038)

CAUTION!
If mechanical damage is found on the 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 entire circuit must be cleaned and the cooler replaced if necessary.

Removing

- Remove the engine cover/upper air filter housing. Refer to => [ Engine Cover/Upper Air Filter Housing ] Engine Cover/Upper Air Filter Housing.

- Remove intake tube - item 11 -=> [ Intake Tube ] Engine Cover/Upper Air Filter Housing Overview from the turbocharger.

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

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





- Remove the charge air hose clamp - arrow - and hose 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 (HO2S) (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 line bolt - 3 -.

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





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





- Remove the vent tube bolts - 1 -, vent tube 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 to turbocharger.

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

- Remove the upper front exhaust pipe to turbocharger nuts.





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





- Remove the lower front exhaust pipe to turbocharger nuts.





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





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





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

• Catalytic converter is not removed and oxygen sensor connector is not disconnected.

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





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





- Unscrew the bolts - 1 and 2 - and remove the turbocharger support.





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

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





- Pull the engine approximately 20 mm toward the rear using (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 nuts - arrows -.





- Remove the turbocharger/exhaust manifold upward.

Installing

CAUTION!
If mechanical damage is found on the 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 entire circuit must be cleaned and the cooler replaced if necessary.

Installation is performed in the reverse order of removal, noting the following:

• Hose connections with connection couplings. Refer to => [ Hose Connections with Connector Couplings, Connecting ] Hose Connections With Connection Couplings, Assembly.

• Always replace seals, gaskets and self locking nuts.

• Add oil to the turbocharger through the oil feed line connection.

• Coolant return line - item 7 -=> [ Coolant Return Line ] Turbocharger Component Overview 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 lubricated with connector couplings. Refer to => [ Hose Connections with Connector Couplings, Connecting ] Hose Connections With Connection Couplings, Assembly.

• Secure all hose connections using hose clamps appropriate for the model type. Refer to the parts catalog.

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

Tightening specifications, refer to => [ Turbocharger Overview ] Turbocharger Component Overview.





1 Replace

2 Use hot bolt paste, refer to the parts catalog