Turbocharger

Turbocharger

Special tools, testers and auxiliary items required

• Torque wrench (5-50 Nm) (VAG 1331)

• Spring type clip pliers (VAS 5024A)

• Tensioning strap (T10038)

CAUTION!
If mechanical damage is found on the turbocharger, for example, a destroyed compression wheel, it is not enough to just replace the turbocharger. Perform the following steps to prevent subsequent damage.

• Clean all oil lines.

• Change the engine oil and filter.

• Check the air filter housing, the air filter element and the intake hoses for contamination.

• Check entire charge air circuit and cooler for contamination.

If contaminants are found in the charge air circuit, the circuit must be cleaned and the cooler replaced if necessary.

Removing

- Remove the engine cover/upper air filter housing. Refer to => [ Engine Cover/Upper Air Filter Housing ] Engine Cover/Upper Air Filter Housing.

- Drain the cooling system. Refer to => [ Draining and Filling ] Draining and Filling.

- Remove the front part of the right wheel housing liner. Remove bolts - 1 through 3 - to do so.





- Remove the right charge air hose - arrow - from the charge air cooler.





- Remove the charge air bolts - arrows - and disconnect the charge air pipe.





- Disconnect the electrical connectors - 1 and 2 -.





- Disconnect the electrical connector - arrow - for the Heated Oxygen Sensor (HO2S) and free up the wire.





- Remove the plenum chamber bulkhead.

- Disconnect the electrical connectors from the ignition coils and set the wiring harness aside.





- Disconnect the coolant hose - arrow - from the expansion tank.





- Disconnect the coolant hoses - 1 and 2 -.





- Remove the coolant line bracket bolt - 3 -.

- Disconnect the upper coolant hose from the heater core - arrow -.





- Remove the shield with coolant pipe bolts - arrows -.





- Remove the crankcase ventilation line heat shield bolts - 1 - from the turbocharger.





- Disconnect the crankcase ventilation line from the cylinder head cover - 2 - and remove it.

- Disconnect the connecting hose - 3 - from the turbocharger to the cylinder head cover.

- Remove the oil supply line banjo bolt - 4 - from the turbocharger.

- Remove both upper nuts - arrows - of the front exhaust pipe/turbocharger.





- Remove right drive axle heat shield bolts - arrows - and shield.





- Remove both lower nuts - arrows - of the front exhaust pipe/turbocharger.





- Remove the exhaust system suspended mount bolts - arrows -.





- Loosen the clamping sleeve nuts - arrows - and remove the exhaust system.





- Disconnect the front exhaust pipe from the turbocharger and slide it toward the rear slightly.

• The catalytic converter is not removed and the oxygen sensor electrical connector is not disconnected.

- Remove the oil supply line and coolant supply line bolts - arrows - from the turbocharger.





- Remove the oil return line bolts - arrows - from the turbocharger.





- Remove the turbocharger support bolts - 1 and 2 - and remove the support for the turbocharger.





• The following step is necessary to achieve some more room between the cylinder head and bulkhead.

- Remove the pendulum support bolts - 2 and 3 -.





- Pull the engine approximately 20 mm toward the rear using the (T10038).





- Disconnect the coolant pipe - arrow -.





- Remove the coolant pipe bracket bolt - 1 -.





• The bolt - 1 - is installed only on coolant pipes with two brackets.

- Remove the exhaust manifold/turbocharger upper nuts - arrows -.

- Remove exhaust manifold/turbocharger upward.

Installing

CAUTION!
If mechanical damage is found on the turbocharger, for example, a destroyed compression wheel, it is not enough to just replace the turbocharger. Perform the following steps to prevent subsequent damage.

• Clean all oil lines.

• Change the engine oil and filter.

• Check the air filter housing, the air filter element and the intake hoses for contamination.

• Check the entire charge air circuit and cooler for contamination.

If contaminants are found in the charge air circuit, the circuit must be cleaned and the cooler replaced if necessary.

Installation is performed in reverse order. When doing this note the following:

• Connect the hose connections with connector couplings. Refer to => [ Hose Connections with Connector Couplings ] Hose Connections with Connector Couplings.

• Always replace seals, gaskets and self locking nuts.

• Add oil to the turbocharger through the oil supply line hole.

• Coolant return line must be installed together with the turbocharger.

• Hose connections and charge air system hoses must be free of oil and grease before installing. Sealing ring and sealing surfaces on the connector couplings must only be lightly lubricated. Refer to => [ Hose Connections with Connector Couplings ] Hose Connections with Connector Couplings.

• Secure all hose connections with hose clamps.

• After installing the turbocharger, let the engine idle for approximately 1 minute to ensure adequate oil supply to the turbocharger.

- Install the exhaust system and align it free of tension. Refer to => [ Exhaust System, Installing ] Exhaust System, Installing.

- Fill the cooling system. Refer to => [ Draining and Filling ] Draining and Filling.

Tightening Specifications