Turbocharger
Turbocharger
Special tools, testers and auxiliary items required
• Bits (T10099)
• Bit XZN 10 (T10154)
• Torque wrench 5-50 Nm (VAG 1331)
• Spring type clip pliers (VAS 5024A) or hose clip pliers (VAS 6362)
• Engine bung set (VAS 6122)
• Hot bolt paste (G 052 112 A3)
CAUTION!
If mechanical damage was found on the turbocharger, for example a destroyed compression wheel, just replacing the turbocharger is not enough. Perform the following steps to prevent subsequent damage.
• Check the air filter housing, the air filter insert and the intake hoses for contamination.
• Check entire charge air circuit and cooler for contamination.
If contaminants are found in charge air circuit, circuit must be cleaned and cooler replaced if necessary.
Removing
• To perform work sequence, the ground cable must be disconnected from the battery. Check whether a coded radio is installed. If so, obtain the anti theft code beforehand.
- Remove the engine cover. Refer to --> [ Engine Cover ] Engine Cover.
- Remove the air filter. Refer to --> [ Air Filter ] Air Filter.
CAUTION!
Risk of destroying electrical components when the battery is disconnected:
• Observe measures when disconnecting the battery.
- With the ignition off, disconnect the ground cable - arrow - from the battery..
- Remove the battery, battery tray bolts - arrows - and battery tray.
- Remove the noise insulation.
- Remove right front wheel.
- Remove the right front wheel housing liner.
- Drain the cooling system. Refer to --> [ Draining and Filling ] [1][2]Cooling System, Draining and Filling.
- Remove the front exhaust pipe with catalytic converter. Refer to --> [ Front Exhaust Pipe with Catalytic Converter ] Service and Repair.
- Remove the charge air pipe bolts - arrows -.
- Remove the charge air pipe by lifting the clamps - 1 and 2 -.
- Disconnect the electrical connectors - 1 and 2 - and free up the electrical wire - arrows -.
- Remove the right drive axle heat shield bolts - arrows - and shield.
- Remove the bolts - 1 - using the (T10154).
- Remove bolt - 2 -.
- Remove the banjo bolt - 2 - and move the coolant line to the side.
- Remove the bolts - 1 - for the oil return line.
- Remove the bolt - 3 - for the oil supply line.
- Disconnect the electrical connectors - arrows - from the ignition coils with output stages and lay the wiring harness to the side.
- Disconnect the coolant hose leading to the coolant expansion tank- arrow -.
- Disconnect the vacuum line - 1 - at the separating point - 2 - and free up the wire.
- Remove the coolant hoses - arrows - from the coolant pipe.
- Remove the bolt - 4 - and the ground wire - 3 -.
- Remove the charge air pipe bolt - arrow -.
- Loose the hose clamp - 2 - and lay the charge air pipe on the cylinder head.
- Seal the turbocharger using the (VAS 6122).
- Remove the bolts - 1 though 3 - and remove the heat shield together with the coolant pipe.
• Remove the heat shield bolt - 2 - using a 6 mm hex head socket - A -. The hex socket must be at least 5 cm - B - long. A socket that tapers to 6 mm at the tip is too wide.
- Disconnect the oil supply line from the turbocharger - 4 -.
- Disconnect the coolant hose - arrow - and move it to the side.
- Remove the nuts - arrows -.
- Remove the turbocharger/exhaust manifold upward.
Installing
CAUTION!
If mechanical damage was found on the turbocharger, for example a destroyed compression wheel, just replacing the turbocharger is not enough. Perform the following steps to prevent subsequent damage.
• Check the air filter housing, the air filter insert and the intake hoses for contamination.
• Check entire charge air circuit and cooler for contamination.
If contaminants are found in charge air circuit, circuit must be cleaned and cooler replaced if necessary.
Install in reverse order of removal. When doing this note the following:
• Hose connections and charge air system hoses must be free of oil and grease before installing. Sealing ring and sealing surfaces must only be lightly oiled with connector couplings. Refer to --> [ Charge Air Hose Connector Coupling, Disconnecting and Connecting ] Charge Air Hose Connector Coupling, Disconnecting and Connecting.
• Secure all hose connections using hose clamps appropriate for the model type.
• Assemble the charge air hose connections. Refer to --> [ Charge Air Hose Connector Coupling, Disconnecting and Connecting ] Charge Air Hose Connector Coupling, Disconnecting and Connecting.
• Always replace seals, gaskets and self locking nuts.
• Coat the stud bolts on the exhaust manifold with hot bolt paste (G 052 112 A3).
• Add oil to turbocharger through the oil feed line connecting piece.
• After installing the turbocharger, let the engine idle for approximately 1 minute without increasing engine speed. This ensures adequate oil supply to the turbocharger.
• Coolant return line must be installed together with turbocharger.
- Observe the notes after connecting the battery.
- Check the coolant level. Refer to --> [ Draining and Filling ] [1][2]Cooling System, Draining and Filling.