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
Engine Bung Set VAS 6122
Drip Tray VAS 6208

Removing

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.
Clean the charge air circuit if foreign objects are found in the charge air system. Replace the charge air cooler if necessary.

-- Remove the front -1- and rear -2- noise insulation. Refer to Removal and Installation .

Fig 1: Front Noise Insulation -1 And 2-

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

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

-- Remove the right front wheel.

-- Remove the right noise insulation -arrows-.

Fig 2: Identifying Right Drive Axle Heat Shield

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-- Remove right drive axle heat shield from bevel box -arrows-.

Fig 3: Identifying Right Drive Axle Heat Shield

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-- Raise the retaining clip -3- and remove the bolt -4-.

Fig 4: Locating Banjo Bolt

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-- Place the VAS 6208 under engine.

-- Remove the banjo bolt -1- for the coolant supply line -2- and oil supply line. Lay the lines aside.

-- Remove the bolts -arrows- and the oil supply line from the turbocharger.

Fig 5: Identifying Oil Return Line

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

Fig 6: Identifying Bolts And Support For Turbocharger

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-- Disconnect the connector -1- and free up the wiring harness -arrows-.

Fig 7: Identifying Wiring Harness

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-- Remove the bolts -arrows-. Remove the air guide pipe from the turbocharger leave it in the installation position.

Fig 8: Identifying Charge Air Pipe Bolts

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-- Remove the hose -2- from the EVAP canister from the cylinder head cover.

Fig 9: Locating EVAP Canister Hose

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-- Remove the bolts -3- and then remove the crankcase ventilation tube and heat shield from the cylinder head cover by loosening the hose clamp -1-.

-- Disconnect the connectors -1- from the ignition coils.

Fig 10: Identifying Crankcase Ventilation Line Between High Pressure Pump And Cylinder Crankcase

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-- Move the electrical wiring harness to the left.

NOTE:

Ignore -2, 3 and 4-.

-- Disconnect the coolant hose from -arrow- from the coolant reservoir.

Fig 11: Disconnecting Coolant Line To Coolant Expansion Tank

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

Fig 12: Identifying Coolant Hoses

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-- Remove the bolt -3- and the coolant ventilation line.

-- Remove the coolant hose -arrow-.

Fig 13: Coolant Pipe

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-- Remove the nuts -arrows- and remove the turbocharger with the exhaust manifold upward.

Fig 14: Identifying Turbocharger/Exhaust Manifold Upper Nuts

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NOTE:

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

Installing

Tightening specifications, refer to TURBOCHARGER OVERVIEW , CHARGE AIR COOLER OVERVIEW .

Installation is done is reverse order, observe 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.

The hose supports, air guide pipes and hoses must be free of oil and grease before installing.

Secure all hose connections with hose clamps appropriate for the model.

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 coolant ventilation line. Refer to COOLANT PIPES OVERVIEW .

-- Follow the instructions for installing the air guide pipes and hoses with connector couplings. Refer to AIR GUIDE PIPES AND HOSES WITH CONNECTOR COUPLING .

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

-- Engine oil level, checking.

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

-- Fill with coolant COOLING SYSTEM, DRAINING AND FILLING => Filling .