Turbocharger, Removing And Installing: Removing

WARNING: This page is about a different car, the 2012 Volkswagen Touareg and 2011 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 .

-- Loosen the spring clamps -arrows- and remove the air guide hose.

Fig 1: Air Guide Pipe, Remove/Install

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-- Remove the bolts -2 and 3-.

Fig 2: Bolts -2 And 3-.

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-- Loosen the clamp -1- and remove the air duct pipe from the air duct hose forward.

-- Remove the bolts -left arrows- and move the air intake connection to the side with the air duct hose still connected -right arrow-.

Fig 3: Identifying Air Intake Connector & Air Duct Hose

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-- Disconnect the connector -2- on the Turbocharger 1 Servo Motor -V280-.

Fig 4: Identifying Bolt -1- And Banjo Bolt -3- And Move Turbocharger Oil Supply Line To Side

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-- Remove the bolt -1- and banjo bolt -3- for the oil supply line on the turbocharger.

-- Remove the bolts -1-. Just loosen bolt -3-.

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NOTE:

Only vehicles with engine codes CASA and CASD have the vacuum line and bracket -2-.

-- Move the vacuum hose and bracket -2- to the side and remove the heat shield from the turbocharger.

-- Cover the opening -arrow- in the transmission to prevent small parts from falling inside.

Fig 5: Locating Transmission Opening

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NOTE:

The illustration shows the connecting pipe removed.

Ignore -Item 1- and -item 2-.

-- Remove the nuts -arrows- and remove the pre-catalytic converter from the turbocharger.

Fig 6: Identifying Front Exhaust Pipe With Catalytic Converter Nuts

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-- Disconnect the -3- Exhaust Gas Temperature Sensor 1 -G235- connector (black).

Fig 7: Installed Location for the Exhaust Cleaning System Connector

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-- Remove the turbocharger bolts -arrows-.

Fig 8: Locating Turbocharger Bolts

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Fig 9: Identifying Turbocharger Components

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CAUTION:

Danger of damaging both pipes for the oil return line.

The upper part -3- of the oil return line mounted to the turbocharger must be removed carefully from the lower part -5- of the oil return line.
Gently turning the turbocharger -4- back and forth and pulling it up will prevent bending the oil return line pipes.

O-Ring
Intermediate Flange

-- Remove the turbocharger.

-- Seal the open lines and connections with clean plugs from the Engine Bung Set:VAS6122 .

NOTE:

Do not set the removed turbocharger on top the upper part of the oil return line.