Turbocharger, Removing And Installing: Removing

WARNING: This page is about a different car, the 2014 Volkswagen Touareg and 2013 Volkswagen Touareg. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION:

If mechanical damage (such as a destroyed compression wheel) is found on the turbocharger, just replacing the turbocharger is not enough. To avoid damage later, perform the following steps:

Check the air filter housing, air filter element and air guide hoses for contamination.
Check the entire charge air circuit and charge air cooler for foreign objects.
If there are foreign objects in the charge air system, clean the charge air circuit and replace the charge air cooler if necessary.

-- Remove the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

-- Remove the noise insulation. Refer to OVERVIEW - NOISE INSULATION .

Vehicles with Reducing Agent Injector -N474-, Version 2:

-- Remove the Reducing Agent Injector -N474-. Refer to Reducing Agent Injector -N474-, REMOVING AND INSTALLING .

Continuation for All Vehicles:

Fig 1: Air Guide Pipe, Remove/Install

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-- Loosen the hose clamps -arrows- to remove the air duct pipe.

-- Unclip the coolant line on the air duct pipe.

-- Remove the crankcase ventilation hose -1- from the turbocharger. Press the releases to do this.

Fig 2: Identifying Crankcase Ventilation Hose

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NOTE:

Depending on the market-specific vehicle version, crankcase ventilation hoses may be used that cannot be removed from the cylinder head cover without being destroyed.

Do not remove the hose on the cylinder head cover.

-- Remove the connector -2- from the bracket and disconnect it.

Fig 3: Identifying Connector

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-- Free up the wire.

-- If equipped, remove the connector -arrow- from the bracket.

Fig 4: Identifying Connector At Bracket

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-- Unclip the vacuum line and move to the side.

-- Release the connector -arrow- and remove.

Fig 5: Identifying Connector

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-- Free up the wiring harness and hoses on the wiring guide -1- using the : 80-200 .

Fig 6: Bolts -2 And 3- And Remove The Wiring Guide -1-

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-- Pull the coolant hose toward the rear -arrow-.

-- Remove the bolts -2 and 3- and remove the wiring guide -1-.

-- Remove the bolt -arrow- from the tab on the pre-catalytic converter.

Fig 7: Identifying Bolt -Arrow- From Exhaust Pipe

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-- Remove the particulate filter bracket bolts -1 and 2-.

Fig 8: Identifying Left Main Catalytic Converter Bracket Bolts And Nuts

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-- Then disengage the inner bracket and push the particulate filter to the side.

-- Remove the nuts -arrows-.

Fig 9: Preliminary Catalytic Converter Flange Nuts

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-- Remove the exhaust pipe from the turbocharger and move it as far as possible to the side.

-- Remove the bolts -arrows-.

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-- Push the coolant pipe -2- upward.

-- Loosen the hose clamp -1-.

Fig 10: Removing Air Guide Pipe From Turbocharger

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-- Remove the bolts -arrows- and then remove the air duct pipe from the turbocharger.

-- Remove the bolts -2-.

Fig 11: Locating Bolts

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-- Loosen the screw-type clamp -1- and then remove the EGR pipe.

-- Remove the breather hose -B- from the clip on the coolant pipe.

Fig 12: Coolant Pipes, Breather Hose & Clips

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-- Remove the coolant pipes -A- from the transmission -arrows-.

-- Loosen and remove the bolts -2- from below.

Fig 13: Identifying Bolts -1 And 2-

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-- Loosen and remove the upper and rear bolt -1- from above.

-- Place the Socket Bit XZN 10: T10501 on the lower front bolt from above.

-- Loosen this bolt from the left wheel housing using a suitable extension. Remove the bolt from the above.

-- Loosen the bolt -5-.

Fig 14: Identifying Turbocharger, Bolts And Nuts

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-- Remove the nuts -1 and 2- and the bolt -3 and 4-.

-- Remove the turbocharger.

-- Seal the open connections with suitable plugs from the : VAS6122 .