Turbocharger And Exhaust Manifold
Special tools and workshop equipment required
- Torque Wrench (5-50 Nm) V.A.G 1331
- Follow the safety precautions when working on the charge air system and turbocharger. Refer to SAFETY PRECAUTIONS .
- Observe the rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .
Always follow these instructions before and during work.
Removing
If mechanical damage is found on the 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 element and the intake hoses for contamination. Refer to AIR FILTER HOUSING OVERVIEW .
If foreign objects are found in the charge air system:
- Check the entire charge air circuit and the charge air cooler for foreign objects. Refer to CHARGE AIR COOLER COMPONENT OVERVIEW .
- Replace the connecting pipe -item 29- in TURBOCHARGER AND EXHAUST MANIFOLD WITH ATTACHMENTS OVERVIEW between the exhaust manifold and intake manifold.
- Clean the entire charge air circuit and replace the charge air cooler if necessary.
- Check the housing and the Exhaust Gas Recirculation (EGR) cooler for foreign objects. Refer to EXHAUST GAS RECIRCULATION SYSTEM COMPONENT OVERVIEW .
- Check the oil lines on the turbocharger for contamination and foreign objects. Refer to TURBOCHARGER AND EXHAUST MANIFOLD WITH ATTACHMENTS OVERVIEW .
-- Remove the particulate filter with NOx reduction catalytic converter. Refer to PARTICULATE FILTER WITH NOX REDUCTION CATALYTIC CONVERTER .
The exhaust gas temperature sensor 1 -G235- covers the upper threaded connector on the turbocharger support and must not be bent. It must be removed.
-- Remove the Exhaust Gas Temperature (EGT) sensor 1.
-- Remove the control line -item 8- in EXHAUST GAS RECIRCULATION SYSTEM COMPONENT OVERVIEW between the EGR housing and the exhaust pressure sensor 2 -G451-.
-- Remove the housing with the EGR cooler. Refer to EXHAUST GAS RECIRCULATION SYSTEM COMPONENT OVERVIEW .
-- Disconnect the connector from the charge pressure actuator position sensor -G581- -2- at the vacuum diaphragm.
-- Disconnect the vacuum hose -3- from the vacuum diaphragm.
-- Disconnect the >>black<< connector for the EGT sensor 1 -2- at the plenum chamber bulkhead.
-- Guide the wire out of the mount on the plenum chamber bulkhead and on the turbocharger.
-- Remove the connecting pipe -item 31- in TURBOCHARGER AND EXHAUST MANIFOLD WITH ATTACHMENTS OVERVIEW .
-- Remove the oil supply line. Refer to OIL SUPPLY LINE TO TURBOCHARGER .
-- Remove the banjo bolt from the turbocharger support.
-- Remove the stud bolt -item 17- in TURBOCHARGER AND EXHAUST MANIFOLD WITH ATTACHMENTS OVERVIEW from the turbocharger support.
-- Rotate the lower section of the support 90° and remove the support downward from the upper section.
-- Remove the heat shield -item 16- in TURBOCHARGER AND EXHAUST MANIFOLD WITH ATTACHMENTS OVERVIEW from the exhaust manifold.
-- Remove the exhaust manifold nuts.
-- Remove the turbocharger with the exhaust manifold from the cylinder head and rotate it so the intake side faces down. Remove the turbocharger with the exhaust manifold downward.
Installing
Before installing, check if the oil return pipe coupling element is bent and therefore stretched. If that is the case, tiny cracks can form that can lead to leaks. Replace the oil return pipe before installing the turbocharger if necessary.
Install in reverse order of removal. When doing this note the following:
- Always replace self-locking nuts, seals, gaskets and clamps.
- Insert the turbocharger with the pressure side upward.
- Position the charge air pipe connecting hose before securing the turbocharger.
- Make sure EGT sensor 1 is installed correctly. Refer to Figure.
- Replace the banjo bolt with the turbocharger support gaskets and oil return pipe O-rings.
- Do not stretch the oil return pipe coupling element when installing the turbocharger support.