Turbocharger with Exhaust Manifold
Turbocharger with Exhaust Manifold
Special tools, testers and auxiliary items required
• Torque Wrench (V.A.G 1331)
CAUTION!
• Follow the safety precautions when working on the charge air system and turbocharger. Refer to --> [ Safety Precautions ] Safety Precautions.
• Observe rules for cleanliness. Refer to --> [ Clean Working Conditions ] Clean Working Conditions.
Always follow these instructions before and during work.
Removing
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. Refer to --> [ Air Filter Assembly Overview ] Air Filter Assembly Overview.
If foreign objects are found in the charge air system:
• Check the entire charge air circuit and the charge air cooler for foreign objects --> [ Charge Air Cooler Components Assembly Overview ] Charge Air Cooler Components Assembly Overview.
• Replace the connecting pipe between the exhaust manifold and intake manifold --> [ 29 Connecting Pipe ] Turbocharger with Exhaust Manifold and Attachments Assembly Overview.
• Clean the entire charge air circuit and replace the charge air cooler if necessary.
• Check the housing and the exhaust gas recirculation cooler for foreign objects --> [ Exhaust Gas Recirculation System Components Assembly Overview ] Service and Repair.
• Check the oil lines on the turbocharger for contamination and foreign objects --> [ Turbocharger with Exhaust Manifold and Attachments Assembly Overview ] Turbocharger with Exhaust Manifold and Attachments Assembly Overview.
- Remove particulate filter with NOx reduction catalytic converter. Refer to --> [ Particulate Filter with NOx Absorption Catalytic Converter ] Particulate Filter with NOx Absorption Catalytic Converter.
- Mark installation position of the exhaust gas temperature sensor 1 --> [ (item 37) , 45 Nm ] Turbocharger with Exhaust Manifold and Attachments Assembly Overview and remove it.
- Remove control wire between the exhaust gas recirculation housing and the exhaust pressure sensor 2 --> [ 8 Control Wire, 23 Nm ] Service and Repair.
- Remove housing with the exhaust gas recirculation cooler. Refer to --> [ Exhaust Gas Recirculation System Components Assembly Overview ] Service and Repair.
- Disconnect connector from the charge pressure actuator position sensor - 2 - at the turbocharger vacuum diaphragm.
- Disconnect vacuum hose - 3 - at the turbocharger vacuum diaphragm.
- Disconnect "black" connector for the exhaust gas temperature sensor 1 - 2 - at the engine bulkhead.
- Guide line out of the retainers on the engine bulkhead and the turbocharger.
- Remove connecting pipe --> [ 31 Connecting Pipe ] Turbocharger with Exhaust Manifold and Attachments Assembly Overview.
- Remove oil supply line. Refer to --> [ Oil Supply Line to Turbocharger ] Service and Repair.
- Remove banjo bolt --> [ (item 24) Banjo Bolt ] Turbocharger with Exhaust Manifold and Attachments Assembly Overview from the turbocharger support.
- Remove hex stud bolt --> [ (item 17) Stud Bolt ] Turbocharger with Exhaust Manifold and Attachments Assembly Overview from the turbocharger support.
- Rotate the lower section of the support 90° and remove the support downward from the upper section.
- Remove heat shield --> [ 16 Heat Shield ] Turbocharger with Exhaust Manifold and Attachments Assembly Overview on the exhaust manifold.
- Remove exhaust manifold nuts --> [ item 15, 23 Nm ] Turbocharger with Exhaust Manifold and Attachments Assembly Overview.
- Remove turbocharger with the exhaust manifold from the cylinder head and rotate it so the intake side faces down. Remove the turbocharger with the exhaust manifold downward.
Installing
CAUTION!
Before installing, check if the oil return pipe decoupling element is bent and therefore stretched. If that is the case, tiny cracks can form that can lead to leaks. Replace the oil return pipe before installing the turbocharger if necessary.
Install in reverse order of removal, noting the following:
• Always replace self-locking nuts, seals, gaskets and clamps.
• Insert turbocharger with the pressure side upward.
• Position charge air pipe connecting hose before securing the turbocharger.
• Note the installation position of exhaust gas temperature sensor 1.
• Replace the banjo bolt with the turbocharger support gaskets and oil return pipe O-rings.
• Do not stretch the oil return pipe decoupling element when installing the turbocharger support.
Tightening Specifications
Refer to:
• --> [ Oil Filter Bracket and Oil Cooler Assembly Overview ] Service and Repair
• --> [ Turbocharger with Exhaust Manifold and Attachments Assembly Overview ] Turbocharger with Exhaust Manifold and Attachments Assembly Overview
• --> [ Charge Air Cooler Components Assembly Overview ] Charge Air Cooler Components Assembly Overview
• --> [ Intake Manifold with Attachments Assembly Overview ] Intake Manifold With Attachments Assembly Overview
• --> [ Particulate Filter with NOx Absorption Catalytic Converter Assembly Overview ] Particulate Filter with NOx Absorption Catalytic Converter Assembly Overview
• --> [ Exhaust Gas Recirculation System Components Assembly Overview ] Service and Repair