Removing and installing turbocharger

Special tools and workshop equipment required

• Engine bung set - VAS 6122-

• Spring-type clip pliers - VAS 6362-
• Release tool - T10527-
• Release tool - T10527/1-

Removing

• Drain coolant ⇒ 1.3 Draining and adding coolant.
• Remove heat shield for drive shaft ⇒ Running gear, axles, steering; Rep. gr. 40; Drive shaft; Removing and installing drive shaft heat shield.

• Unscrew bolts -arrows-.
• Remove oil supply line -1- and oil return line -2-.

• Unscrew bolt -2-.
• Remove screw-type clip -1-.
• Unscrew nuts -arrows- and tie up catalytic converter -3-.
• Remove resonator for intake air ⇒ 3.3 Removing and installing resonator for intake air.
• Remove air pipe ⇒ 2.5 Removing and installing air intake pipe.

• Unscrew bolts -arrows-.

• Cover coolant pump with a cloth.
• Remove crankcase breather hose and place it to one side.

• Remove crankcase breather -1- from camshaft housing -2-.
• Lay crankcase breather -1- to one side.
• Remove connection for turbocharger ⇒ 1.4 Removing and installing connection for turbocharger.

• Unscrew bolts -arrows-.
• Swivel coolant lines -1- to side.

• Unscrew bolts -arrows-.
• Unclip wiring harness for lambda probe from heat shield -1-.
• Remove heat shield -1-.

• Unscrew nuts -arrows- and remove turbocharger.

Installing

Install in reverse order of removal. The following should be observed:

• Fit screwdriver -2- in recess -arrow- on turbocharger.
• Lever out seal -1-.
• Renew oil seal -1-.
• Add coolant ⇒ 1.3 Draining and adding coolant.
• Ensure proper connection and routing of wires ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.

Torque settings

• ⇒ 1.1 Assembly overview - turbocharger
• ⇒ Fig. ““Installing catalytic converter - specified torque and tightening sequence”“, page 343
• ⇒ Running gear, axles, steering; Rep. gr. 40; Drive shaft; Assembly overview - drive shaft