Turbocharger

Turbocharger

Special tools, testers and auxiliary items required

• Bits (T10099)

• Bit XZN 10 (T10154)

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Spring Type Clip Pliers (VAS 5024 A)

• Engine Bung Set (VAS 6122)


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.

• 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.

Removing

- Remove the air filter housing. Refer to => [ Air Filter Housing ] Air Filter Housing.

- Remove the noise insulation.

- Remove the front part of the right wheel housing liner and/or the right front wheel housing liner.

- Drain the coolant. Refer to => [ Draining and Filling ] Procedures.

- Remove engine cover.

- Disconnect the connectors from the ignition coils and the wiring harness and lay them aside.






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






- Disconnect the vacuum line - 1 - at the separating point - 2 - and free up the line.






- Remove the coolant hoses - arrows - from the coolant pipe.

- Disconnect the ground wire - 3 - and loosen the bolt - 4 -.






- Remove the charge air pipe bolt - arrow -.

- Loose the hose clamp - 2 - and lay the charge air pipe on the cylinder head.

- Seal off the turbocharger using the engine bung set (VAS 6122).

- Remove the bolts - 1 though 3 - and remove the heat shield together with the coolant pipe.






• Remove the bolt - 2 - from the heat shield using a 6 mm - A - hex socket. The hex socket must be at least 5 cm - B - long. A socket that tapers to 6 mm at the tip is too wide.






- Remove the oil supply pipe - 4 - from the turbocharger.






- Remove the bolts - arrows -.






- Lift the clamps - 1 and 2 - and remove the charge air pipe.

Vehicles with All Wheel Drive (AWD):






- Remove the bolts - 1 - and heat shield - A - from above the right drive axle.

Vehicles with Front Wheel Drive (FWD):






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

Continuation for all Vehicles:

- Remove the front exhaust pipe with catalytic converter. Refer to => [ Front Exhaust Pipe with Catalytic Converters ] Front Exhaust Pipe with Catalytic Converters.






- Disconnect the connectors - 1 and 2 - and free up the wire - arrows -.






- Remove the bolts- 1 - using the Bit XZN 10 (T10154).

- Remove the bolt - 2 -.

- Remove the banjo bolt - 2 - and move the coolant pipe to the side.






Vehicles with FWD:

- Remove the bolts - 1 - for the oil return pipe.

Vehicles with AWD:

- Remove the oil return pipe bolts from the crankcase.

Continuation for all Vehicles:

- Remove the bolt - 3 - for the oil supply pipe.

- Disconnect the coolant hose - arrow - and move it to the side.






- Remove the nuts - arrows -.






- Remove the turbocharger upward.

Installing


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.

• 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 the reverse order of removal, noting the following:

• Assembly of hose connections with connection couplings. Refer to => [ Charge Air Hose, Installing ] Charge Air Hose, Installing.

• Always replace seals, gaskets and self-locking nuts.

• Add oil to the turbocharger through the oil supply pipe connecting piece.

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

• The coolant return pipe => [ (Item 5) Coolant Return Pipe ] Turbocharger Component Overview must be installed together with the turbocharger.

• Hose connections and charge air system hoses must be free of oil and grease before installing. On connector couplings, the seal and sealing surfaces must only be lightly oiled. Refer to => [ Charge Air Hose, Installing ] Charge Air Hose, Installing.

• Secure all hose connections using hose clamps appropriate for the model type.

Tightening specifications, refer to => [ Turbocharger Component Overview ] Turbocharger Component Overview.






1 replace nuts

2 Use hot bolt paste.