Removal And Installation: Turbocharger

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Hose Clip Pliers V.A.G 1921
Tensioning Strap T10038
Ring Spanner 7-Piece Set 3337
Engine Bung Set VAS 6122

CAUTION:

If mechanical damage is found on the exhaust 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 insert and the intake hoses for contamination.
Check entire charge air circuit and cooler for contamination.

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

Removing

-- Disconnect the electrical connector on the mass airflow (MAF) sensor -G70- -3-.

Fig 1: Mass Air Flow (MAF) Sensor G70 Electrical Harness Connector, Clips & Front Air Intake Connector On Lock Carrier

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-- Open clips -1 and 2- and remove air guide hose from MAF sensor.

-- Remove front air intake connector on lock carrier -4-.

-- Remove engine cover.

-- Remove air guide hose -arrow- with the V.A.G 1921.

Fig 2: Identifying Air Guide Hose

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-- Disconnect connector -1- from ignition coils.

Fig 3: Identifying Crankcase Ventilation Line Between High Pressure Pump And Cylinder Crankcase

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WARNING:

Cover cap of expansion tank with a rag and open carefully, as hot steam or hot coolant may escape when opening.

-- Open cap of coolant expansion tank.

-- Drain the coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .

-- Disconnect the coolant line to coolant expansion tank -arrow-.

Fig 4: Disconnecting Coolant Line To Coolant Expansion Tank

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-- Disconnect coolant hose -1-.

Fig 5: Identifying Coolant Hoses

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-- Disconnect coolant hose -2-.

-- Remove coolant line -3-.

NOTE:

The illustration depicts the engine removed from behind.

-- Remove the heat shield -arrows-.

Fig 6: Heat Shield Bolts

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-- Remove crankcase ventilation line with heat shield from turbocharger -1-.

Fig 7: Identifying Crankcase Ventilation With Heat Shield, Crankcase Ventilation From Cylinder Head Cover, Oil Supply Line & EVAP Canister Line

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-- Pull off the crankcase ventilation line from the cylinder head cover -2- and remove it.

-- Disconnect EVAP line to turbocharger from cylinder head cover -3-.

-- Remove oil supply line from turbocharger -4-.

-- Remove electrical connector -arrow- for the heated oxygen sensor (HO2S) -G39- and oxygen sensor (O2S) heater -Z19- before catalytic converter from the bracket, disconnect it and lay it aside.

Fig 8: Disconnecting Heated Oxygen Sensor (HO2S) G39 Harness Connector

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-- Remove the heated oxygen sensor (HO2S) 2 -G39- -arrow- using a tool from the 3337.

Fig 9: Oxygen Sensor

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-- Remove catalytic converter with front exhaust pipe. Refer to FRONT EXHAUST PIPE WITH CATALYTIC CONVERTERS AND FRONT MUFFLER .

-- Remove center noise insulation fasteners -1 to 4-.

Fig 10: Center Noise Insulation Fasteners And Center Noise Insulation Panel

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-- Remove the right noise insulation -arrows-.

Fig 11: Identifying Right Noise Insulation -Arrows-

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-- Remove noise insulation frame -arrow-.

Fig 12: Identifying Noise Insulation Frame

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-- Remove right drive axle. Refer to Removal and Installation .

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

Fig 13: Identifying Protective Cap For Drive Axle On Engine

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-- Disconnect air guide pipe -arrow- from charge air cooler.

Fig 14: Charge Air Cooler Air Guide Pipe

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-- Unfasten air duct from turbocharger -arrows-.

Fig 15: Turbocharger Air Duct And Connector

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-- Disconnect the connector -1 and 2- and free up the cable.

-- Remove bolts -arrows- and remove air guide pipe.

Fig 16: Identifying Charge Air Pipe Bolts

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NOTE:

The illustration depicts the engine removed from behind.

-- Remove the oil supply line from the turbocharger -2-.

Fig 17: Cylinder Block And Turbocharger Oil Supply Line

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-- Remove coolant supply line to turbocharger -2-.

Fig 18: Turbocharger Coolant Supply Line Connections

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-- Disconnect oil return line -arrows- on turbocharger.

Fig 19: Identifying Oil Return Line

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-- Remove bolts -1- and -2- and remove support for turbocharger.

Fig 20: Identifying Bolts And Support For Turbocharger

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-- Remove bolts -1 - 3- and remove pendulum support.

Fig 21: Identifying Pendulum Support & Bolts

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-- Install bolt -1-.

Fig 22: Rotating Engine With Special Tool T10038

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-- Rotate engine forward with the T10038.

NOTE:

Make sure the engine and turbocharger move freely.

-- Disconnect coolant pipe -arrow-.

Fig 23: Identifying Coolant Pipe

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NOTE:

The illustration depicts the engine removed from behind.
Nuts on bottom of fastening strip do not need to be opened.

-- Remove the upper nuts -arrows-.

Fig 24: Identifying Turbocharger/Exhaust Manifold Upper Nuts

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-- Remove turbocharger/exhaust manifold upward.

Installing

Install in reverse order of removal. Note the following:

For the correct tightening specifications, refer to TURBOCHARGER OVERVIEW .

NOTE:

Always replace seals, gaskets and self-locking nuts.
Add oil to turbocharger through oil feed line connecting piece.
Hose connections and charge air system hoses must be free of oil and grease before installing.
Secure all hose connections using hose clamps appropriate for the model type.

-- Install turbocharger in position shown.

Fig 25: Identifying Turbocharger

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-- Install exhaust system and align it free of tension. Refer to EXHAUST SYSTEM, ALIGNING .

-- Install the heated oxygen sensor (HO2S) -G39-. Refer to Removal and Installation .

-- Install drive axle. Refer to Removal and Installation .

-- Air guide pipes with connector, installing. Refer to HOSE CONNECTIONS WITH CONNECTOR COUPLINGS, ASSEMBLING .

-- Fill with coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .

-- Check oil level.

NOTE:

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