Remove exhaust turbocharger

WARNING: Hot surfaces.
Risk of burning!

Perform all work only on components that have cooled down.

NOTE: RISK OF DAMAGE
Electrostatic discharge.
Damage to or destruction of electrical components.

Leave the electrical components in their original packaging until they are being installed. Only use the original packaging for returning the product. Always package removed components straight away.
Read and comply with user information on using the associated special tool 12 7 060.
Only tap the housings of electrical components. Do not tap pins or multi-pin connectors directly.
Wear electrically conductive clothing and antistatic shoes (with ESD symbol).
For additional information see: NOTES ON ESD (ELECTROSTATIC DISCHARGE) PROTECTION

NOTE: Prior to replacing the exhaust turbocharger: Observe the notes on troubleshooting on the exhaust turbocharger.

NOTE: For exhaust turbocharger damage: Check the pressure pipes, charge air cooler and intake plenum for foreign matter, damage and correct functionality.

NOTE: If the oil return line is exchanged, then the connecting pipe to the oil sump must ALWAYS be cleaned, as the connecting pipe can coke.

Preliminary work

Refer to REMOVING THE FRONT UNDERBODY PROTECTION OR FRONT THRUST FIELD .
Refer to REMOVING THE FRONT THRUST FIELD .
Refer to REMOVING THE STIFFENING PLATE .
Refer to REMOVING THE CONNECTING SUPPORT FROM THE TUNNEL .
Refer to REMOVING COMPLETE EXHAUST SYSTEM .
Refer to REMOVING THE ACOUSTIC COVER .
Refer to REMOVING THE COVER ON LEFT AND RIGHT IN THE ENGINE COMPARTMENT AT THE TOP .
Refer to REMOVING THE LEFT AND RIGHT FRONT-END STRUT .
Refer to REMOVING INTAKE SILENCER HOUSING .
Refer to REMOVING THE RESONATOR WITH THE TOP CLEAN AIR PIPE .
Refer to REMOVING BOTTOM CLEAN AIR PIPE .
Refer to REMOVING CHARGE AIR LINE .
Refer to REMOVING FRONT CROSS CONNECTION .
Refer to REMOVING THE REAR TOP CROSS CONNECTION .
Refer to REMOVING THE FAN COWL .
Refer to DRAINING THE COOLANT FROM THE HIGH-TEMPERATURE COOLING SYSTEM .
Refer to REMOVING THE LAMBDA OXYGEN SENSOR .
Refer to REPLACING THE OXYGEN MONITOR SENSOR .
Refer to REMOVING CATALYTIC CONVERTER .
Refer to REMOVING THE OIL RETURNING LINE FOR THE EXHAUST TURBOCHARGER .
Refer to REMOVING THE FRONT SECTION OF THE COOLANT RETURN LINE .
Refer to REMOVING THE COOLANT FEED LINE (COOLANT RETURN LINE IS REMOVED) .
Refer to REMOVING HEAT SHIELD FOR CYLINDER HEAD COVER .

Unscrew the guide pin (1).

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Unlock plug connection (1) and disconnect.

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Loosen screw (1).
Release screw (2) and remove the support.

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Loosen screw (1).
Detach oil feed line from engine block.

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Install the special tool 2 446 919 on the exhaust turbocharger and secure it with the bolt (1).
Make sure that the special tool 2 446 919 is flush with the exhaust turbocharger in the marked area.

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Secure the special tool 2 446 919 by turning the clamping lever (1) in the direction of the arrow.
NOTE: The clamping lever that is shown in the graphic is already in its end position.

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Position the holder (1) and fasten it with the bolt (2).
NOTE: Holder 1 is used for the final mounting of the special tool 2 446 919.

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Position the retainer (1) and secure it with the nuts (2).

TIGHTENING TORQUES SPECIFICATION

U bolt to special tool 2 919 (446)
The tightening torque must be observed! Risk of damage to the exhaust manifold!	Tightening torque	1 Nm

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Position the retainer (1) and secure it with the nuts (2).

TIGHTENING TORQUES SPECIFICATION

U bolt to special tool 2 919 (446)
The tightening torque must be observed! Risk of damage to the exhaust manifold!	Tightening torque	1 Nm

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Release nuts in the order (7) till (1) in semicircular pattern.
Secure exhaust turbocharger against falling down.

Fig 1: Exhaust Turbocharger Nuts Loosening Sequence
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Remove the sliding rail (1).

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NOTE: Do not damage the thermal compensating elements. Disassembly and installation including intermediate storage of the exhaust turbocharger is only permitted with mounted special tool 2 466 919.
Thermal compensating element of the exhaust turbocharger (1) or exhaust manifold should not be bent or deformed.
Carefully guide out and remove the exhaust turbocharger (1).

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