Removal And Installation: Turbocharger

Special tools and workshop equipment required

Hose clamps up to 25 mm dia. 3094
Torque wrench V.A.G 1331
Torque wrench V.A.G 1410
Spring-type clip pliers VAS 5024A
Drip tray for workshop crane VAS 6208
Torque wrench V.A.G 1332

CAUTION:

If mechanical damage is found on exhaust turbocharger, e.g. a destroyed compression wheel, it is not enough to just replace the turbocharger. Perform the following steps to prevent subsequent damage.

Clean all oil lines.
Change the engine oil and the oil filter.
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 charge air circuit, circuit must be cleaned and cooler replaced if necessary.

Removing

-- Remove engine cover.

One Piece Engine Cover

Fig 1: Identifying Removal Of One Piece Engine Cover

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Pull the one piece front engine cover -arrows A- upward with a quick jerk and then pull the lower mount -arrow B- forward.

Two Piece Engine Cover

Fig 2: Identifying Removal Of Two Piece Engine Cover

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On the two piece engine cover, first pull the outer cover upward with a quick jerk -arrows in the upper illustration-, then pull the inner engine cover upward with a quick jerk -arrows in lower illustration-.

-- Disconnect electrical harness connector -2- at Mass Air Flow (MAF) sensor -G70-.

Fig 3: Identifying Ventilation Hose -1-, Electrical Harness Connector -2-, Spring-Type Clip -3-, Bolt -4- And Intake Manifold -5-

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-- Disconnect the ventilation hose -1- and disengage it from the bracket -arrow-.

-- Open the spring-type clip -3- using spring-type clip pliers VAS 5024A and disconnect the intake hose from the Mass Air Flow (MAF) sensor -G70-.

-- Disconnect the intake manifold -5- from the air guide.

-- Unfasten bolt -4- and remove air filter housing and mass air flow sensor.

-- Disconnect the vacuum hoses -1- through -3- from the intake hose -4-.

Fig 4: Identifying Vacuum Hoses -1- Through -3- And Intake Hose -4-

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-- Remove the turbocharger intake hose -4-.

-- Carefully cut the cable tie -1-.

Fig 5: Identifying Cable Tie

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-- Remove both bolts -arrows- from the upper charge air pipe -A-.

Fig 6: Identifying Bolts To Upper Charge Air Pipe

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-- Remove noise insulation Removal and Installation .

-- Remove the charge air pipe bolt -arrow- -A- from the oil pan.

-- Remove the turbocharger charge air pipe and pull it as far forward as possible

-- Remove bolts -2- and -3- of pendulum support.

Fig 7: Identifying Pendulum Support & Bolts

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-- Disconnect the transmission oil cooler hoses using hose clamps 3094.

Fig 8: Identifying Coolant Hoses Clamped Using Clamps 3094

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-- Remove the air guide bolt -2-.

Fig 9: Identifying Air Guide Bolt -2-

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-- Unlatch and disconnect the connectors -1- and -2-.

Fig 10: Identifying Connectors And Hoses

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-- Remove hose -3-.

-- Disconnect vacuum hose -4-.

-- Disengage and disconnect the connector -A-.

Fig 11: Locating Exhaust Gas Recirculation (EGR) Cooler Switch Over Valve -N345-

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-- Remove the front exhaust pipe EXHAUST SYSTEM ASSEMBLY OVERVIEW .

-- Remove the bracket. To do this, remove the nuts -1-.

Fig 12: Identifying Bracket Bolts

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-- Remove the right drive axle from the transmission Removal and Installation .

-- Remove the coolant hoses -1- and -3- using hose clamps 3094, as shown -arrows-.

Fig 13: Identifying Coolant Hoses And Hose Clamps 3094

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-- Open and remove the shield -4-.

-- Remove connecting pipe -2-.

-- Remove the nuts -3- and remove the air guide.

Fig 14: Identifying Air Guide Bolt -2-

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-- Remove the pipe/hose line -1-.

Fig 15: Identifying Pipe/Hose Line And Bolts

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-- Remove the bolts -2- and -3- and remove the cooler for the exhaust gas recirculation.

-- Remove the bolts -1-, -2- and -4- and remove the complete oil return line -3- from the cylinder block and the turbocharger.

Fig 16: Identifying Bolts -1-, -2-, -4- And Complete Oil Return Line -3-

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NOTE:

Do not remove the turbocharger -2- after removing the nuts -1- because the oil supply line is still attached to the turbocharger.

Leave 2 loosened nuts -1- on the threaded pins to keep the turbocharger from falling down.

Fig 17: Identifying Nuts From Turbocharger

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-- Remove the nuts -1- from the turbocharger.

-- Remove the union nut -arrow- and disconnect the oil supply line from the turbocharger.

Fig 18: Identifying Union Nut -Arrow- And Oil Supply Line From The Turbocharger

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-- Remove the loosened nuts and remove the turbocharger from the threaded pins.

NOTE:

For the following work steps, a second technician is needed.

-- Push the engine forward and remove the turbocharger downward.

Installing

-- Mount the turbocharger -2- on the threaded pins.

Fig 19: Identifying Nuts From Turbocharger

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-- Secure the turbocharger from falling down. To do this, hand tighten 2 new nuts -1-.

-- Mount the oil supply line onto the turbocharger and tighten the union nut -arrow-.

Fig 20: Identifying Union Nut -Arrow- And Oil Supply Line From The Turbocharger

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-- Install the complete oil return line -3-.

Fig 21: Identifying Bolts -1-, -2-, -4- And Complete Oil Return Line -3-

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-- Replace the bolt -4-.

-- First install loosely all the exhaust gas recirculation cooler bolts -2- and -3-. Then tighten the bolts -2- and -3-.

Fig 22: Identifying Pipe/Hose Line And Bolts

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-- Install the pipe/hose line -1-.

-- Replace the cable tie -1-.

Fig 23: Identifying Cable Tie

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Further installation is performed in reverse order.

Tightening specifications TURBOCHARGER ASSEMBLY OVERVIEW .

-- Fill with coolant COOLING SYSTEM, DRAINING AND FILLING .

-- Check the engine oil level ENGINE OIL, CHECKING LEVEL .

-- Install the pendulum support on the transmission ENGINE AND TRANSMISSION MOUNT TIGHTENING SPECIFICATIONS .