Turbocharger
Turbocharger
Special tools, testers and auxiliary items required
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Follow the safety precautions when working on the charge air system and turbocharger. Refer to => [ Safety Precautions ] Safety Precautions.
• Follow the guidelines for clean working conditions. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
Always follow these instructions before and during work.
Removing
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.
Check the air filter housing, the air filter element and the intake hoses for contamination. Refer to => [ Air Filter Housing ] Air Filter Housing.
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 System Components Overview ] Service and Repair.
• Replace the connecting pipe (- item 29 - in the => [ Turbocharger and Components Overview ] Turbocharger and Components Overview) between the exhaust manifold and intake manifold.
• Clean the entire charge air circuit and replace the charge air cooler, if necessary.
• Check the housing and the Exhaust Gas Recirculation (EGR) cooler for foreign objects. Refer to => [ Exhaust Gas Recirculation System Component Overview ] Service and Repair.
• Check the oil lines on the turbocharger for contamination and foreign objects. Refer to => [ Turbocharger and Components Overview ] Turbocharger and Components Overview.
- Remove the particulate filter with NOx reduction catalytic converter. Refer to => [ Particulate Filter with NOx Reduction Catalytic Converter Overview ] Particulate Filter With NOx Reduction Catalytic Converter Overview.
The exhaust gas temperature sensor 1 covers the threaded connector at the top of the turbocharger support. It must not be bent. It must be removed.
- Remove the exhaust gas temperature sensor 1.
- Remove the control line (- item 8 - in the=> [ Exhaust Gas Recirculation System Component Overview ] Service and Repair) between the Exhaust Gas Recirculation (EGR) housing and the exhaust pressure sensor 2.
- Remove the housing with the EGR cooler => [ Exhaust Gas Recirculation System Component Overview ] Service and Repair.
- Disconnect the connector from the charge pressure actuator position sensor - 2 - from the vacuum diaphragm.
- Disconnect the vacuum hose - 3 - from the vacuum diaphragm and from the turbocharger.
- Disconnect the "black" connector for the exhaust gas temperature sensor 1 - 2 - at the plenum chamber bulkhead.
- Guide the wire out of the mount on the plenum chamber bulkhead and on the turbocharger.
- Remove the connecting pipe - item 31 - in the => [ Turbocharger and Components Overview ] Turbocharger and Components Overview.
- Remove the oil supply line. Refer to => [ Turbocharger Oil Supply Line ] Service and Repair.
- Remove the banjo bolt from the turbocharger support.
- Remove the stud bolt (- item 17 - in the => [ Turbocharger and Components Overview ] Turbocharger and Components Overview) from the turbocharger support.
- Rotate the lower section of the support 90° and remove the support downward from the upper section.
- Remove the heat shield (- item 16 - in the => [ Turbocharger and Components Overview ] Turbocharger and Components Overview) on the exhaust manifold.
- Remove the turbocharger/exhaust manifold nuts.
- Remove the turbocharger/exhaust manifold from the cylinder head and turn it so that the intake side faces downward. Remove the turbocharger/exhaust manifold downward.
Installing
Before installing, check if the oil return pipe coupling 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 the reverse order of removal. Note the following:
• Replace the self-locking nuts, the seals, the gaskets and clamps.
• Insert the turbocharger with the pressure side upward.
• Position the charge air pipe hose before securing the turbocharger.
• Pay attention the exhaust gas temperature sensor 1 installed position. Refer to => [ Installed Position of the Exhaust Gas Temperature Sensor with Angled Shaft ] Turbocharger and Components Overview.
• Replace the banjo bolt with the turbocharger support gaskets and oil return pipe O-rings.
• Do not stretch the oil return pipe coupling element when installing the turbocharger support.