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
Hose Clip Pliers VAS 6340
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 the charge air circuit, circuit must be cleaned and cooler replaced if necessary.

Removing

-- Remove the noise insulation. Refer to Removal and Installation .

-- Remove the right noise insulation -arrows-.

Fig 1: Identifying Right Drive Axle Heat Shield

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-- Remove the frame for the noise insulation. Refer to Removal and Installation .

-- Drain the coolant. Refer to COOLANT, DRAINING AND FILLING .

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

-- Remove the bolts -arrows-.

Fig 2: Air Guide Pipe And Bolts

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-- Lift the clamps -1 and 2- and remove the air guide pipe.

NOTE:

The installation location is shown with the engine removed.

-- Disconnect electrical connectors -1 and 2- and free up electrical wire -arrows-.

Fig 3: Identifying Turbocharger Electrical Connectors

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

Fig 4: Identifying Turbocharger Support And Bolts

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-- Remove the banjo bolt -2- and move the coolant line to the side.

Fig 5: Identifying Oil Return Line, Coolant Line And Oil Supply Line Fasteners

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-- Remove the bolts -1- on the oil return line.

-- Remove the bolt -3- on the oil supply line.

-- Remove the engine cover -arrows-.

Fig 6: Identifying Engine Cover, Removal

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NOTE:

The installation location is shown with the engine removed.

-- Remove the air guide pipe bolt -arrow-.

Fig 7: Locating Air Guide Pipe Bolt

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-- Remove the air guide pipe; to do this, loosen the hose clamp -1-.

-- Press the release buttons and remove the air guide hose -2-.

NOTE:

The installation location is shown with the engine removed.

-- Remove the coolant hose -1-.

Fig 8: Locating Coolant Hose Bolts

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-- Remove the bolts -2 and 3-.

-- Remove the coolant hoses -1 and 2-.

Fig 9: Identifying Coolant Hoses

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-- Remove the bolts -3- and the coolant line.

NOTE:

Be careful of the ground wire -arrow- when installing.

-- Disconnect the coolant hose -arrow- and move it to the side.

Fig 10: Coolant Hose Clamps

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-- Remove the heat shield -arrows-.

Fig 11: Turbocharger And Heatshield

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-- Disconnect the oil supply line from the turbocharger -1-.

-- Remove the line -3-.

Fig 12: Camshaft Position Sensor Electrical Harness Connector

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-- Remove the nuts -arrows-.

Fig 13: Identifying Turbocharger/Exhaust Manifold Upper Nuts

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-- Remove the turbocharger with the exhaust manifold upward.

NOTE:

To prevent dirt from entering, seal open lines and connections on the turbocharger with clean plugs or protective caps.

Installing

For the correct tightening specifications, refer to TURBOCHARGER OVERVIEW .

Installation is carried out in the reverse order while noting the following:

NOTE:

Replace the seals, O-rings and the self-locking nuts.

Fill the turbocharger with engine oil at the oil supply line connection.

Hose connections and charge air system hoses must be free of oil and grease before installing.

Secure all hose connections with hose clamps of the same type as those equipped by the factory.

To ensure the turbocharger is supplied with enough oil, let the engine run at idle for approximately 1 minute after installing the turbocharger. Do not increase the engine speed during this time.

-- Install the turbocharger and exhaust manifold; tightening sequence. Refer to Figure.

-- Install the front exhaust pipe with the catalytic converter and front muffler. Refer to FRONT EXHAUST PIPE WITH CATALYTIC CONVERTERS AND FRONT MUFFLER .

-- Install exhaust system free of stress. Refer to EXHAUST SYSTEM, ALIGNING .

-- Air guides, installing with connector. Refer to AIR GUIDE PIPES AND HOSES WITH CONNECTOR COUPLING .

-- Fill the coolant system. Refer to COOLANT, DRAINING AND FILLING => Filling: .

-- Check oil level. Refer to ENGINE OIL LEVEL, CHECKING .