Turbocharger Component Overview
Turbocharger Component Overview
• Hose connections and charge air system hoses must be free of oil and grease before installing. The sealing ring and sealing surfaces for the connector couplings must only be lightly oiled. Refer to => [ Charge Air Hose, Disconnecting and Connecting ] Charge Air Hose, Disconnecting and Connecting.
• Only use approved clamps for hose connections. Refer to the Parts Catalog.
• The charge air system must be properly sealed.
• Replace the self-locking nuts.
• Use spring type clip pliers to install spring clamps.
• Charge air hose disconnecting and connecting. Refer to => [ Charge Air Hose, Disconnecting and Connecting ] Charge Air Hose, Disconnecting and Connecting.
• Add oil to the turbocharger through the oil supply pipe 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.
I - => [ Wastegate Bypass Regulator Valve and Turbocharger Recirculation Valve ]
II - => [ Coolant Supply and Oil Pipes ]
III - => [ Turbocharger and Coolant Return Pipe ]
IV - => [ Vacuum Diaphragm ]
Wastegate Bypass Regulator Valve and Turbocharger Recirculation Valve
1 Turbocharger
• Can be replaced only with the exhaust manifold.
• Coat the stud bolts on the exhaust manifold with hot bolt paste, for the hot bolt paste refer to the Parts Catalog.
• Removing and installing, refer to => [ Turbocharger ] Turbocharger.
2 Connecting Hose
• Make sure it is secure.
3 Turbocharger Vacuum Diaphragm
• Checking, refer to => [ Turbocharger Vacuum Diaphragm, Checking ] Testing and Inspection.
• Removing and installing, refer to => [ Turbocharger Vacuum Diaphragm ] Service and Repair.
4 Hose
• Make sure it is secure.
5 Hose
• Make sure it is secure.
6 Bolt
• 3 Nm
7 Wastegate Bypass Regulator Valve (N75)
8 Hose
• Make sure it is secure.
9 Connection
10 Clip
11 Bolt
• 9 Nm
12 Seal
13 Turbocharger Recirculation Valve (N249)
• Note the installed position, refer to => [ Installed Position of the Turbocharger Recirculation Valve ].
14 Bolt
• 7 Nm
15 Seal
Installed Position of the Turbocharger Recirculation Valve
- Note the installed position - arrows -.
Coolant Supply and Oil Pipes
1 Seal
• Always replace.
2 Banjo Bolt
• 33 Nm
3 Oil Supply Pipe
4 Turbocharger
• Can only be replaced with the exhaust manifold.
• Coat the stud bolts on the exhaust manifold with hot bolt paste, for the hot bolt paste refer to the Parts Catalog.
• Removing and installing, refer to => [ Turbocharger ] Turbocharger.
5 Bolt
• 9 Nm
6 Bolt
• 9 Nm
7 Seal
• Always replace.
8 Banjo Bolt
• 38 Nm
9 Bolt
• 9 Nm
10 Banjo Bolt
• 38 Nm
11 Seal
• Always replace.
12 Coolant Supply Pipe
13 O-ring
• Always replace.
14 Bolt
• 9 Nm
15 Gasket
• Always replace.
16 Oil Return Pipe
17 Bolt
• 9 Nm
18 Gasket
• Always replace.
Turbocharger and Coolant Return Pipe
1 Gasket
• Always replace.
2 Nut
• Always replace.
• Coat the stud bolts on the exhaust manifold with hot bolt paste, for the hot bolt paste refer to the Parts Catalog.
• Tightening sequence and specification, refer to => [ Turbocharger Nut Tightening Sequence and Specification ].
3 Banjo Bolt
• 38 Nm
4 Seal
• Always replace.
5 Coolant Return Pipe
6 Bolt
• 9 Nm
7 Turbocharger
• Can only be replaced with the exhaust manifold.
• Coat the stud bolts on the exhaust manifold with hot bolt paste, for the hot bolt paste refer to the Parts Catalog.
• Removing and installing, refer to => [ Turbocharger ] Turbocharger.
8 Support
9 Bolt
• 30 Nm
• Coat the bolt with hot bolt paste, for the hot bolt paste refer to the Parts Catalog.
10 Bolt
• 30 Nm
• Coat the bolt with hot bolt paste, for the hot bolt paste refer to the Parts Catalog.
11 Nut
• 30 Nm
• Always replace.
• Do not loosen to remove the turbocharger.
• Coat the stud bolts on the exhaust manifold with hot bolt paste, for the hot bolt paste refer to the Parts Catalog.
12 Bracket
Turbocharger Nut Tightening Sequence and Specification
Special tools, testers and auxiliary items required
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Torque Wrench (V.A.G 1783)
Procedure
- Tighten the nuts in 4 passes in sequence - 1 through 5 - as follows:
- Tighten the nuts to 5 Nm.
- Tighten the nuts to 12 Nm.
- Tighten the nuts to 16 Nm.
- Tighten the nuts to 25 Nm.
Vacuum Diaphragm
1 Turbocharger
• Can only be replaced with the exhaust manifold.
• Coat the stud bolts on the exhaust manifold with hot bolt paste, for the hot bolt paste refer to the Parts Catalog.
• Removing and installing, refer to => [ Turbocharger ] Turbocharger.
2 Turbocharger Vacuum Diaphragm
• Checking, refer to => [ Turbocharger Vacuum Diaphragm, Checking ] Testing and Inspection.
• Removing and installing, refer to => [ Turbocharger Vacuum Diaphragm ] Service and Repair.
3 Bolt
• 10 Nm
4 Circlip