Turbocharger
Turbocharger
Special tools, testers and auxiliary items required
• Hose Clip Pliers (V.A.G 1921)
• Tensioning Strap (T10038)
• Ring Spanner 7-Piece Set (3337)
• Engine Bung Set (VAS 6122)
If mechanical damage is found on the exhaust 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 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
- Disconnect the electrical connector on the mass airflow (MAF) sensor (G70) - 3 -.
- Open clips - 1 and 2 - and remove air guide hose from MAF sensor.
- Remove front air intake connector on lock carrier - 4 -.
- Remove engine cover.
- Remove air guide hose - arrow - with the (V.A.G 1921).
- Disconnect connector - 1 - from ignition coils.
Cover cap of expansion tank with a rag and open carefully, as hot steam or hot coolant may escape when opening.
- Open cap of coolant expansion tank.
- Drain the coolant. Refer to => [ Cooling System, Draining and Filling ] Procedures.
- Disconnect the coolant line to coolant expansion tank - arrow -.
- Disconnect coolant hose - 1 -.
- Disconnect coolant hose - 2 -.
- Remove coolant line - 3 -.
• The illustration depicts the engine removed from behind.
- Remove the heat shield - arrows -.
- Remove crankcase ventilation line with heat shield from turbocharger - 1 -.
- Pull off the crankcase ventilation line from the cylinder head cover - 2 - and remove it.
- Disconnect EVAP line to turbocharger from cylinder head cover - 3 -.
- Remove oil supply line from turbocharger - 4 -.
- Remove electrical connector - arrow - for the heated oxygen sensor (HO2S) (G39) and oxygen sensor (O2S) heater (Z19) before catalytic converter from the bracket, disconnect it and lay it aside.
- Remove the heated oxygen sensor (HO2S) 2 (G39) - arrow - using a tool from the (3337).
- Remove catalytic converter with front exhaust pipe. Refer to => [ Front Exhaust Pipe with Catalytic Converters and Front Muffler ] Service and Repair.
- Remove center noise insulation fasteners - 1 to 4 -.
- Remove the right noise insulation - arrows -.
- Remove noise insulation frame - arrow -.
- Remove right drive axle.
- Remove the right drive axle heat shield - arrows -.
- Disconnect air guide pipe - arrow - from charge air cooler.
- Unfasten air duct from turbocharger - arrows -.
- Disconnect the connector - 1 and 2 - and free up the cable.
- Remove bolts - arrows - and remove air guide pipe.
• The illustration depicts the engine removed from behind.
- Remove the oil supply line from the turbocharger - 2 -.
- Remove coolant supply line to turbocharger - 2 -.
- Disconnect oil return line - arrows - on turbocharger.
- Remove bolts - 1 - and - 2 - and remove support for turbocharger.
- Remove bolts - 1 - 3 - and remove pendulum support.
- Install bolt - 1 -.
- Rotate engine forward with the (T10038).
• Make sure the engine and turbocharger move freely.
- Disconnect coolant pipe - arrow -.
• The illustration depicts the engine removed from behind.
• Nuts on bottom of fastening strip do not need to be opened.
- Remove the upper nuts - arrows -.
- Remove turbocharger/exhaust manifold upward.
Installing
Install in reverse order of removal. Note the following:
• For the correct tightening specifications, refer to => [ Turbocharger Overview ] Turbocharger Overview.
• Always replace seals, gaskets and self-locking nuts.
• Add oil to turbocharger through oil feed line connecting piece.
• Hose connections and charge air system hoses must be free of oil and grease before installing.
• Secure all hose connections using hose clamps appropriate for the model type. Refer to the electronic parts catalog ETKA.
- Install turbocharger in position shown.
- Install exhaust system and align it free of tension. Refer to => [ Exhaust System, Aligning ] Exhaust System, Aligning.
- Install the heated oxygen sensor (HO2S) (G39).
- Install drive axle.
- Air guide pipes with connector, installing. Refer to => [ Hose Connections with Connector Couplings, Assembling ] Hose Connections with Connector Couplings, Assembling.
- Fill with coolant. Refer to => [ Cooling System, Draining and Filling ] Procedures.
- Check oil level.
• After installing turbocharger, let engine idle for approximately 1 minute without increasing engine speed. This ensures adequate oil supply to the turbocharger.