Turbocharger Component Overviews
Turbocharger Component Overviews
• Secure all hose connections using hose clamps appropriate for the model type.
• Hose connections and charge air system hoses must be free of oil and grease before installing. The sealing ring and sealing surfaces must only be lightly oiled with the hose couplings. Refer to => [ Charge Air Hose, Installing ] Charge Air Hose, Installing.
• The charge air system must be properly sealed.
• Replace the self-locking nuts.
• Spring type clip pliers (VAS 6499) or hose clamp pliers (V.A.G 1921) are recommended for installing spring clamps.
• Fill the turbocharger with engine oil at the oil supply pipe connection.
• After installing the turbocharger, let the engine idle for approximately 1 minute. The engine must not increase in engine speed. This ensures there is adequate oil supply to the turbocharger.
• Pay attention to the rules of cleanliness. Refer to => [ Clean Working Conditions ] Service Precautions.
I - => [ Turbocharger and Coolant Return Pipe ]
II - => [ Coolant Supply and Oil Pipes ]
III - => [ Wastegate Bypass Regulator Valve and Intake Tube ]
Turbocharger and Coolant Return Pipe
1 Gasket
• Always replace.
2 Nut
• 20 Nm
• Always replace.
• Coat the stud bolts for the exhaust manifold with hot bolt paste.
• For the hot bolt paste, refer to the Parts Catalog.
3 Banjo Bolt
• 35 Nm
4 Seal
• Always replace.
5 Bolt
• 9 Nm
6 Bolt
• 23 Nm
• Installed with 2 brackets only on the coolant return pipe.
7 Coolant Return Pipe
• Gradual introduction of coolant return pipes with a bracket.
8 Turbocharger
• Removing and installing, refer to => [ Turbocharger ] Turbocharger.
9 Support
10 Bolt
• 30 Nm
• Coat the bolt with hot bolt paste.
• For the hot bolt paste, refer to the Parts Catalog.
11 Bolt
• 30 Nm
• Coat he bolt with hot bolt paste.
• For the hot bolt paste, refer to the Parts Catalog.
12 Support
13 Bolt
• 23 Nm
14 Nut
• 30 Nm
• Do not loosen to remove the turbocharger.
• Always replace.
• Coat the stud bolts on the exhaust manifold with hot bolt paste.
• For the hot bolt paste, refer to the Parts Catalog.
15 Bracket
Coolant Supply and Oil Pipes
1 Seal
• Always replace.
2 Banjo Bolt
• 30 Nm
3 Oil Supply Pipe
4 Turbocharger
• Removing and installing, refer to => [ Turbocharger ] Turbocharger.
5 Bolt
• 9 Nm
6 Banjo Bolt
• 30 Nm
7 Seal
• Always replace.
8 Banjo Bolt
• 35 Nm
9 Seal
• Always replace.
10 Coolant Supply Pipe
11 Bolt
• 23 Nm
12 Banjo Bolt
• 35 Nm
13 Bolt
• 9 Nm
14 Seal
• Always replace.
15 Gasket
• Always replace.
16 Oil Return Pipe
17 Bolt
• 9 Nm
18 Gasket
• Always replace.
Wastegate Bypass Regulator Valve and Intake Tube
1 Turbocharger
• Can only be replaced with the exhaust manifold and vacuum diaphragm.
• Removing and installing, refer to => [ Turbocharger ] Turbocharger.
2 Hose
• To the Evaporative Emission (EVAP) canister.
3 Gasket
• Always replace.
4 Bolt
• 9 Nm
5 Heat Shield
6 Vent Tube
7 Intake Tube
• Note the installed position, refer to => [ Installed Position of the Intake Tube ].
8 Seal
• Always replace.
9 to the Turbocharger Recirculation Valve
• See - item 29 - in => [ Charge Air Cooler Overview ] Charge Air Cooler Overview.
10 Clamp
11 Gasket
• Note the installed position, refer to => [ Installed Position of the Intake Tube ].
12 Vacuum Diaphragm
• Checking, refer to => [ Turbocharger Vacuum Diaphragm, Checking ] Testing and Inspection.
13 Connection
14 Hose
15 Seal
• Always replace.
16 Banjo Bolt
• 8 Nm
17 Hose
18 Bolt
• 3 Nm
19 Wastegate Bypass Regulator Valve (N75)
20 Hose
21 Seal
• Always replace.
22 Connection
23 Clip
24 Bolt
• 9 Nm
Installed Position of the Intake Tube
