Turbocharger

Turbocharger

Special tools, testers and auxiliary items required

• Hose Clip Pliers (V.A.G 1921)

• Hose Clip Pliers (VAS 6340)

• 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 the charge air circuit, circuit must be cleaned and cooler replaced if necessary.

Removing

- Remove the noise insulation.

- Remove the right noise insulation - arrows -.






- Remove the frame for the noise insulation.

- Drain the coolant. Refer to => [ Coolant, Draining and Filling ] Service and Repair.

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

- Remove the bolts - arrows -.






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

• The installation location is shown with the engine removed.

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






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






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






- Remove the bolts - 1 - on the oil return line.

- Remove the bolt - 3 - on the oil supply line.

- Remove the engine cover - arrows -.






• The installation location is shown with the engine removed.

- Remove the air guide pipe bolt - arrow -.






- Remove the air guide pipe; to do this, loosen the hose clamp - 1 -.

- Press the release buttons and remove the air guide hose - 2 -.

• The installation location is shown with the engine removed.

- Remove the coolant hose - 1 -.






- Remove the bolts - 2 and 3 -.

- Remove the coolant hoses - 1 and 2 -.






- Remove the bolts - 3 - and the coolant line.

• Be careful of the ground wire - arrow - when installing.

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






- Remove the heat shield - arrows -.






- Disconnect the oil supply line from the turbocharger - 1 -.

- Remove the line - 3 -.






- Remove the nuts - arrows -.






- Remove the turbocharger with the exhaust manifold upward.

• To prevent dirt from entering, seal open lines and connections on the turbocharger with clean plugs or protective caps.

Installing

• For the correct tightening specifications, refer to => [ Turbocharger Overview ] Turbocharger Overview.

Installation is carried out in the reverse order while noting the following:

• Replace the seals, O-rings and the self-locking nuts.

• Fill the turbocharger with engine oil at the oil supply line connection.

• Hose connections and charge air system hoses must be free of oil and grease before installing.

• Secure all hose connections with hose clamps of the same type as those equipped by the factory. Refer to the Electronic Parts Catalog (ETKA).

• To ensure the turbocharger is supplied with enough oil, let the engine run at idle for approximately 1 minute after installing the turbocharger. Do not increase the engine speed during this time.

- Install the turbocharger and exhaust manifold; tightening sequence. Refer to => [ Turbocharger - Tightening Sequence ] Turbocharger Overview.

- Install the front exhaust pipe with the catalytic converter and front muffler. Refer to => [ Front Exhaust Pipe with Catalytic Converters and Front Muffler ] Service and Repair.

- Install exhaust system free of stress. Refer to => [ Exhaust System, Aligning ] Service and Repair.

- Air guides, installing with connector. Refer to => [ Air Guide Pipes and Hoses with Connector Coupling ] Service and Repair.

- Fill the coolant system. Refer to => [ Filling: ] Service and Repair.

- Check oil level.