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 5024A)

• 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.

• Clean all oil lines.

• Change the engine oil and the oil filter.

• Check the air filter housing, the air filter element and the intake hoses for contamination.

• Check the entire charge air circuit and the cooler for contamination.

If contaminants are found in the charge air circuit, the circuit must be cleaned and the cooler replaced if necessary.

The oil supply line must be replaced when installing a new turbocharger.

Removing

- Remove the engine cover. Refer to => [ Engine Cover ] Engine Cover.

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

- Remove the noise insulation.

- Remove the right front wheel.

- Remove the right front rear wheel housing liner.

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

- Disconnect the connectors - arrows - from the ignition coils with output stages and lay the wiring harness to the side.






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






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






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

- Disconnect the ground wire - 3 - and remove 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 the turbocharger using plugs from the engine bung set (VAS 6122).

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






• Remove the heat shield bolt - 2 - using a 6 mm hex 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.






- Remove the bolt and the oil supply line from the turbocharger - 4 -.






- Remove the bolts - arrows -.






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

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






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

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






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






- Remove the 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 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.

• Clean all oil lines.

• Change the engine oil and the oil filter.

• 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.

The oil supply line must be replaced when installing a new turbocharger.

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

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 and Pipe, Disconnecting and Connecting ] Charge Air Hose and Pipe, Disconnecting and Connecting.

• Install only approved clamps for securing hose connections.

• Charge air hose connecting and disconnecting, refer to => [ Charge Air Hose and Pipe, Disconnecting and Connecting ] Charge Air Hose and Pipe, Disconnecting and Connecting.

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

• Lubricate the stud bolts on the exhaust manifold with hot bolt paste.

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

• After installing the turbocharger, let the engine idle for approximately 1 minute without increasing the engine speed. This ensures adequate oil supply to the turbocharger.

• The coolant return line => [ (Item 5) Coolant Return Line ] Turbocharger Component Overviews must be installed together with turbocharger.

- Follow the notes after connecting the battery.

- Check the coolant level. Refer to => [ Draining and Filling ] Service and Repair.