Turbocharger: Service and Repair

Turbocharger, removing and installing (engine code AAZ)

Note: It is strongly recommended that penetrating oil be applied to all nuts and bolts in the turbo exhaust track prior to attempting removal. Failure to do so may result in seized nuts, and/or broken studs.

WARNING:
Do not re-use fasteners that are worn or deformed in normal use.
Some fasteners are designed to be used only once, and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts, washers, circlips and cotter pins. Always follow recommendations in this manual-replace these fasteners with new parts where indicated, and any other time it is deemed necessary by inspection.

Note: All hose connections are secured with clips. Charge air pressure must be leak free. Replace self-locking nuts.

Observe rules for cleanliness.


Special Tools, Testers And Auxiliary Items

- 3205 swivel wrench
- VAG1331 torque wrench, 5 to 50 Nm
- High temperature (2000°F) anti-seize compound

Removing:
- Switch ignition off.

CAUTION: Before disconnecting the battery, determine the correct coding for the anti-theft radio.

- Disconnect battery Ground strap.

- Remove hoses between intake manifold to turbocharger and turbocharger to air cleaner.
- Disconnect oil supply line from turbocharger and mounting clip from intake manifold.
- Disconnect oil return line at turbocharger.
- Disconnect exhaust pipe from turbocharger and exhaust manifold support.






- Remove 3 mounting bolts (arrows) between turbocharger and exhaust manifold (using either box wrench or 3205 swivel wrench).

Installing

When installing observe the following

- Install turbocharger and tighten exhaust pipe mounting nuts so that turbocharger can still be moved slightly.
- Install 3 mounting bolts and tighten fully, then tighten exhaust pipe nuts.
- Before attaching oil supply line, fill turbocharger connections with engine oil.

CAUTION: After installing the turbocharger, let engine idle for approx. 1 minute. DO NOT rev-up the engine at first! (This ensures that the turbocharger is properly lubricated).