Part I
Charge Air System With Turbocharger
NOTE: All hose connections are secured with clamps.
Charge air system must be properly sealed.
Always replace self-locking nuts.
Charge pressure hoses and their connections must be free of grease before re-installation.
VAS5024 assembly tool or VAG1921 pliers are recommended for installing spring clips.
Observe rules for cleanliness. [1][2]Technician Safety Information
Observe safety precautions. Technician Safety Information
Note: Minor deviations may be possible depending on vehicle equipment.
- Noise insulation: Bolted to lock carrier
- Bolt: Qty. 2
- Bolt: Qty. 4
- Lock washer: Qty. 4
- Remove noise insulation panel -arrows-
- Remove left-side noise insulation -arrows-
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.
Note: Some vehicles may require the passenger's side drive shaft to be disconnected from the transmission or removed to get required clearance. Refer to Transmission and Drivetrain - Drive Axles, Bearings and Joints - Axle Shaft Assembly - Service and Repair - Procedures Service and Repair
Removal
a. Remove airbox assembly with all attached sensors
b. Remove air duct between charge air cooler and intake manifold
c. Remove intake air duct between charge air cooler and turbocharger.
d. Remove oil and coolant lines connected to turbo unit
e. Remove heat shielding, if required for clearance.
f. Disconnect downpipe and catalytic assembly
g. Unbolt turbocharger from exhaust manifold, remove turbo unit.
Installation
- Installation is reverse of removal.
Editor Note: Oil supply lines for turbo along with engine oil and filter should be replaced when installing a replacement turbocharger.
- Prior to reinstalling turbo unit, remove any remaining gasket material and ensure that turbo mounting surface is clean. Reinstall with new gasket.
- Before restarting engine be sure to prime turbo oil supply.
Before starting vehicle, the turbocharger oil drain hose should be disconnected from the oil pan and the engine should be turned over with starter until oil is running out of the oil drain hose. This will ensure that the turbo is lubricated before initial start-up.
Turbocharger system components, removing & installing
Part I
1. 40 Nm
Coat threads with G 052 112 A3
2. Seal
3. 10 Nm
Must not be loosened
4. Pressure unit
For charge regulator valve in turbocharger
Can only be replaced in conjunction with turbocharger
Checking charge pressure regulation, refer to Testing and Inspection - Procedures Testing and Inspection
5. Circlip
6. Turbocharger
Checking charge air pressure control, refer to Testing and Inspection - Procedures Testing and Inspection
Charge air pressure control valve and charge air pressure control valve vacuum unit are components of the turbocharger and cannot be replaced individually.
Fill turbocharger with oil via connection before connecting oil supply pipe.
After installing turbocharger run engine at idling speed for approx. 1 minute and do nut rev up, to ensure oil supply for turbocharger.
7. O-ring
Always replace
8. 10 Nm
9. Intake pipe
10. Gasket
Always replace
Note installed position
11. 20 Nm
12. Heat shield
13. 10 Nm
14. Banjo bolt, 30 Nm
15. Oil supply pipe
16. 30 Nm
Always replace
Coat threads and bolt head seating surface with G 052 112 A3
17. Exhaust manifold
18. Gasket
Always replace
Note installed position
19. 20 Nm
20. Banjo bolt, 30 Nm
21. 25 Nm
Always replace
Coat threads with G 052 112 A3
22. Banjo bolt, 35 Nm
23. Coolant return pipe
24. 25 Nm
25. Spacer sleeve
26. Banjo bolt, 35 Nm
27. 10 Nm
28. Coolant supply pipe
29. Banjo bolt, 35 Nm
30. 30 Nm
use only original bolts from parts catalog
31. Support bracket
Between turbocharger and cylinder block
32. 25 Nm
33. Gasket
Always replace
34. Gasket
Always replace
35. 10 Nm
36. Oil return pipe
To oil pan
37. 10 Nm
38. 10 Nm
Do not alter setting
Must not be loosened.