Turbocharger, removing and installing

Fig 1: Identifying Special Tools - Turbocharger, Removing And Installing

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Special tools and miscellaneous equipment required

V.A.G 1383 A transmission jack with universal support V.A.G1359/2
3287A Ball joint puller
V.A.G 1332 Torque wrench

40-200 Nm

Removing

NOTE: The turbocharger is removed from below.

Remove engine cover panel (complete).
Remove both front wheels.

Fig 2: Removing Noise Insulation

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Remove noise insulation (bottom and right).

Fig 3: Removing Coupling Link Nut From Stabilizer Bar

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Remove coupling link nut from stabilizer bar.
Remove Torx socket bolt for noise insulation (left).
Remove upper nut on ball joint.

Fig 4: Installing Ball Joint Splitter

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Install ball joint splitter as shown in illustration and press out ball joint.

NOTE: To protect swivel joint threads leave nut on a few turns.

Fig 5: Identifying Subframe Bolts, Steering Gear Bolts & Pendulum Support Bolts

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Remove bolts -1- for steering box and bolts -2- for pendulum support.
Detach rubber mount for front exhaust pipe.
Place engine/transmission jack V.A.G 1383 A with universal support 1359/2 under subframe.
Remove bolts -3- and -4- for sub-frame.

Take out subframe carefully.
Remove heat shield for right-hand drive shaft.
Remove front exhaust pipe. Refer to Exhaust system components, removing and installing .

NOTE: Do not bend the flexible connection (de-coupling element) in the exhaust system more than 10° , otherwise it may be damaged.

Fig 6: Removing Oil Return Pipe From Turbocharger

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Remove oil return pipe from turbocharger using a 5 mm hex socket wrench with ball joint.
Loosen bolt on turbocharger bracket a few turns, but to not remove bolt.
Drain cooling system. Refer to Draining

Fig 7: Removing Intake Air Duct

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Remove air intake pipe between turbocharger and charge air cooler.
Disconnect secondary air hose -1- from air cleaner housing.

Fig 8: Identifying Air Hose, Connectors, Bolts & Mass Air Flow Sensor

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Detach air intake hose -2- at Mass air flow sensor.
Disconnect electrical connectors for air mass meter -3-.
Remove bolts -4- and -5- and remove air cleaner housing.

Fig 9: Detaching Intake Air Hose Between Air Cleaner And Turbocharger

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Detach air intake hose between air cleaner and turbocharger as follows:
Disconnect connector at Wastegate Bypass Regulator Valve -N75-.
1- Connection at air cleaner
2- Detach pressure control valve for crankcase breather -8- from hose.

3- Disconnect vacuum hose for air recirculation valve at connection on cylinder head.
4- Detach hose from Wastegate Bypass Regulator Valve -N75- at air intake pipe.
5- Detach hose from air recirculation valve at air intake pipe.
6- Detach connection to active charcoal filter at non-return valve.

7- Detach connection between Wastegate Bypass Regulator Valve -N75- and pressure unit for charge air pressure control.
8- Detach air intake hose at connection on turbocharger and remove hose.
Remove heat shield above exhaust manifold.

Fig 10: Removing/Installing Coolant Return Pipe & Oil Supply Pipe

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Disconnect coolant return pipe -1- from turbocharger using an 8 mm hex socket wrench with ball joint.

Fig 11: Removing Turbocharger From Exhaust Manifold

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Remove turbocharger from exhaust manifold.
Remove gasket between turbocharger and exhaust manifold and tilt turbocharger slightly away from engine.

Fig 12: Removing/Installing Coolant Return Pipe & Oil Supply Pipe

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Disconnect oil supply pipe -2- from turbocharger using an 8 mm hex socket wrench with ball joint.

Fig 13: Identifying Turbocharger, Coolant Supply Pipe & Turbocharger Bracket Bolt

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Disconnect bracket for coolant return line from turbocharger -1- at crankcase.
Disconnect coolant supply pipe -2- from crankcase using an 8 mm hex socket wrench with ball joint.
Remove bolt on turbocharger bracket completely.
Lower out turbocharger with coolant supply line connected.

Installing:

Note the following points when installing:

Before installing turbocharger, connect coolant supply line and attach retaining bar to turbocharger.

Fig 14: Identifying Turbocharger, Coolant Supply Pipe & Turbocharger Bracket Bolt

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Guide in turbocharger from below and slide onto bracket. Tighten bolt -3- finger-tight.
Slide bracket for coolant return line together, install bolt -1- and tighten to 10 Nm.
Bolt coolant supply line -2- to crankcase (banjo bolt: 35 Nm; bracket -1-: 10 Nm).

NOTE: When tightening connection for coolant supply pipe -2-, make sure line does not turn out of position on turbocharger.

Fig 15: Removing/Installing Coolant Return Pipe & Oil Supply Pipe

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Attach oil supply line -2- and retaining bar to turbocharger (banjo bolt: 30 Nm; retaining bar: 10 Nm).
Slide in gasket between exhaust manifold and turbocharger.

Fig 16: Removing Turbocharger From Exhaust Manifold

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Bolt turbocharger to exhaust manifold.

Fig 17: Removing/Installing Coolant Return Pipe & Oil Supply Pipe

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Connect coolant return line -1- (35 Nm).

NOTE: Install front exhaust pipe before installing subframe.

Tighten all bolts to specified torques indicated in table of tightening torques.
Fill up with coolant. Refer to Filling .

NOTE: After installing the turbocharger, run engine for approx. 1 minute at idling speed; do not rev. up immediately. This ensures the turbocharger is properly lubricated.

Tightening torques

Components		Nm
Oil return line to sump		10
Oil return line to turbocharger		10
Coolant supply line to cylinder block		35
Turbocharger bracket to turbocharger *		30
Turbocharger bracket to cylinder block		25
Oil supply line to turbocharger		30
Oil supply line retainer piece to turbocharger		10
Coolant return line to turbocharger		35
Turbocharger to exhaust manifold		50
Drive shaft heat shield to cylinder block		35
Nuts on clamp		40

* Use correct bolt (same as original part)

Before inserting bolts for subframe, position steering gear on subframe and insert bolts.

Fig 18: Seating Threaded Sleeve In Subframe Hole

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The threaded sleeve -1- must seat in subframe hole.

Install ball joint in wheel bearing housing.

Fig 19: Installing New Self-Locking Nut, And Counter-Hold With T40 Torx Bit

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Install new self-locking nut, and counter-hold with T40 Torx key.

NOTE:

Normal commercially available tools (18 mm ring insert such as Stahlwille 732/10 or Hazet 6630c-18) can also be used instead of V.A.G 1332/10.
Make sure that protective boot is not damaged or twisted.

Tightening torques:
Ball joint to wheel bearing housing (use new nuts)	45 Nm
Pendulum support to transmission M 10 x 70 M 10 x 30	50 Nm 50 Nm
Pendulum support to subframe	25 Nm
Steering gear to subframe (use new bolts)	20 Nm + 90°
Coupling link to anti-roll bar (use new nuts)	100 Nm
Subframe to body (use new bolts)	100 Nm + 90°

After installing, check position of steering wheel during a test drive.

If steering wheel is not in straight ahead position the front axle tracking must be checked!