Removal And Installation: Turbocharger

WARNING: This page is about a different car, the 2009 Volkswagen GTI and 2008 Volkswagen GTI. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Bits -T10099-
Bit XZN 10 -T10154-
Torque Wrench (5-50 Nm) -V.A.G 1331-
Spring Type Clip Pliers -VAS 5024 A-
Engine Bung Set -VAS 6122-

CAUTION:

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.
Check the entire charge air circuit and cooler for contamination.

If contaminants are found in the charge air circuit, the circuit must be cleaned and the cooler replaced if necessary.

Removing

-- Remove the air filter housing. Refer to AIR FILTER HOUSING .

-- Remove the noise insulation. Refer to Description and Operation .

-- Remove the front part of the right wheel housing liner and/or the right front wheel housing liner. Refer to FRONT WHEEL HOUSING LINER .

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

-- Remove the engine cover.

-- Disconnect the connectors from the ignition coils and the wiring harness and lay them aside.

Fig 1: Identifying Connectors Of Ignition Coils

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-- Disconnect the coolant line -arrow- from the coolant expansion tank.

Fig 2: Identifying Coolant Line To Coolant Expansion Tank

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-- Disconnect the vacuum line -1- at the separating point -2- and free up the line.

Fig 3: Identifying Vacuum Line -1-, Ground Wire -3- And Bolt -4-

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-- Remove the coolant hoses -arrows- from the coolant pipe.

-- Disconnect the ground wire -3- and loosen the bolt -4-.

Fig 4: Identifying Charge Air Pipe Bolt -Arrow- And Hose Clamp -2-

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

-- Loose the hose clamp -2- and lay the charge air pipe on the cylinder head.

-- Seal off the turbocharger using the engine bung set -VAS 6122-.

-- Remove the bolts -1 though 3- and remove the heat shield together with the coolant pipe.

Fig 5: Identifying Heat Shield Bolts

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NOTE:

Remove the bolt -2- from the heat shield using a 6 mm -A- hex socket. The hex socket must be at least 5 cm -B- long. A socket that tapers to 6 mm at the tip is too wide.

Fig 6: Identifying 6mm Hex Socket -A-, 5cm Long -B-

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-- Remove the oil supply pipe -4- from the turbocharger.

Fig 7: Identifying Heat Shield Bolts

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-- Remove the bolts -arrows-.

Fig 8: Identifying Air Guide Pipe And Bolts

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

Vehicles with All Wheel Drive (AWD)

Fig 9: Identifying, Tool -3247-, Bolts -1- And Heat Shield -A-

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-- Remove the bolts -1- and heat shield -A- from above the right drive axle.

Vehicles with Front Wheel Drive (FWD)

Fig 10: Identifying Drive Axle Heat Shield Bolts And Shield

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-- Remove the right drive axle heat shield bolts -arrows- and shield.

Continuation for all Vehicles

Fig 11: Identifying Turbocharger Electrical Connectors

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

Fig 12: Identifying Turbocharger Support And Bolts

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-- Remove the bolts -1- using the Bit XZN 10 -T10154-.

-- Remove the bolt -2-.

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

Fig 13: Identifying Oil Return Line, Coolant Line And Oil Supply Line Fasteners

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Vehicles with FWD

-- Remove the bolts -1- for the oil return pipe.

Vehicles with AWD

-- Remove the oil return pipe bolts from the crankcase.

Continuation for all Vehicles

-- Remove the bolt -3- for the oil supply pipe.

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

Fig 14: Identifying Coolant Hose Clamps

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-- Remove the nuts -arrows-.

Fig 15: Identifying Turbocharger/Exhaust Manifold Upper Nuts

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-- Remove the turbocharger upward.

Installing

CAUTION:

Check the air filter housing, the air filter element and the intake hoses for contamination.
Check the entire charge air circuit and cooler for contamination.

If contaminants are found in the charge air circuit, the circuit must be cleaned and the cooler replaced if necessary.

Installation is performed in the reverse order of removal, noting the following:

Assembly of hose connections with connection couplings. Refer to CHARGE AIR HOSE, INSTALLING .
Always replace seals, gaskets and self-locking nuts.
Add oil to the turbocharger through the oil supply pipe connecting piece.
After installing the turbocharger, let the engine idle for approximately 1 minute to ensure adequate oil supply to the turbocharger.
The coolant return pipe must be installed together with the turbocharger.
Hose connections and charge air system hoses must be free of oil and grease before installing. On connector couplings, the seal and sealing surfaces must only be lightly oiled. Refer to CHARGE AIR HOSE, INSTALLING .
Secure all hose connections using hose clamps appropriate for the model type.

Component

Exhaust manifold/turbocharger to cylinder head ⁽¹⁾⁽²⁾

Observe the tightening sequence, refer to Figure.

Oil supply pipe to turbocharger (M12 banjo bolt)

Oil return pipe to turbocharger

Coolant supply pipe to turbocharger (M14 banjo bolt)

Turbocharger bracket to cylinder block ⁽²⁾

Turbocharger bracket to turbocharger ⁽²⁾

Right charge air pipe to oil pan

Heat shield to cylinder head M8 and M12

⁽¹⁾	Replace nuts

⁽²⁾	Use hot bolt paste.