Contents: For engines with the letter…⬇ For all cars ⬇ Removal and installation a…⬇ Removal ⬇ Installation ⬇
Remove the right front wheel arch (fender) liner. Remove the front bumper.
For engines with the letter designation BSW
Disconnect plug connector "1" from boost pressure sensor "G71" with intake air temperature sensor "G72" ("2").
For all cars
Disconnect connecting hose "3" from the charge air cooler pipe. Remove the air duct. Disconnect the connecting hose "1" from the charge air cooler "3". Remove screws "2", then remove the charge air cooler "3". Installation is carried out in reverse order.
Removal and installation a turbocharger for an engine with the letter designation BSW
Caution: If mechanical damage to the turbocharger has occurred, e.g. if the centrifugal compressor wheel is damaged, it is not enough to simply replace the turbocharger. To prevent further damage to the engine, the following work must be performed. Check the air filter housing, filter element, and charge air hoses and pipes for contamination. Check all air ducts and the charge air cooler for foreign bodies. If contamination or foreign bodies are detected in the boost pressure system, it is necessary to thoroughly clean all air ducts and, if necessary, also replace the charge air cooler.
Removal
Lift the engine cover at the sides "arrow A" and remove it forward "arrow B".
Remove the upper boost air pipe "1" with connecting hose "2" "arrows". Remove the intake manifold flap actuator "V157". Remove the intake pipe with mechanical EGR valve.
Disconnect intake hose "3" from the mechanical EGR valve. Remove the pipe leading to the crankcase ventilation system "4" from the air guide pipe. Unscrew screws "2" and "5." Loosen spring clamp "1" on the turbocharger and remove the air guide pipe. Remove the lower engine cover.
After removing screw "3", disconnect connecting hose "2" on the charge air cooler -arrow to the right-. Unscrew the protective cover of the propeller shaft from the cylinder block.
Unscrew the "arrow" screws of the right ball joint head.
Remove the right propeller shaft with gearbox. Subsequently, it should be removed and suspended using a wire under the front bumper, outside the engine compartment. Unscrew the swing support "arrow".
Remove the connecting hose "arrow".
Unscrew the engine block oil drain line. After unscrewing screws "1" and "2", remove the turbocharger support.
Disconnect the intake hose from the boost pressure control system vacuum receiver. Remove the front section of the exhaust manifold with the catalytic converter. Unscrew the oil supply line from the turbocharger and the exhaust manifold and set them aside. Remove the EGR connecting pipe between the turbocharger and the EGR cooler. Remove the heat shield from the exhaust manifold. Unscrew the exhaust manifold with the turbocharger from the cylinder head. Remove the turbocharger with the exhaust manifold downwards.
Installation
Installation is carried out in a similar manner, in the reverse order of actions. The following instructions must be observed in this regard. When installing the push-fit air duct, ensure that the locking clamp "arrow" is engaged behind the retaining tabs "A". Check the oil level.
Important: Replace seals, O-rings and self-locking nuts. Fill the turbocharger with engine oil through the connecting pipe of the supply oil line. Before installing the hose connections and the boost air hoses themselves, ensure that they are free of oil and grease. All hose connections must be secured with appropriate hose clamps. After installing the turbocharger, let the engine run for approx. 1 min at idle speed to allow oil to enter the turbocharger.