Removal And Installation: Turbocharger

Special Tools And Workshop Equipment Required 

• Torque wrench (5-50 Nm) VAG 1331
• Spring type clip pliers VAS 5024A
• Tensioning strap T10038

Removing 

-- Remove the engine cover/upper air filter housing. Refer to ENGINE COVER/UPPER AIR FILTER HOUSING .

-- Drain the cooling system. Refer to DRAINING AND FILLING .

-- Remove the front part of the right wheel housing liner. Remove bolts -1 through 3- to do so.

Fig 1: Identifying Right Front Part Of Wheel Housing Liners

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-- Remove the right charge air hose -arrow- from the charge air cooler.

Fig 2: Identifying Charge Air Hose From Charge Air Cooler

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-- Remove the charge air bolts -arrows- and disconnect the charge air pipe.

Fig 3: Identifying Charge Air Pipe Bolts

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-- Disconnect the electrical connectors -1 and 2-.

Fig 4: Disconnecting Turbocharger Recirculating Valve N249 Electrical Harness Connector

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-- Disconnect the electrical connector -arrow- for the Heated Oxygen Sensor (HO2S) and free up the wire.

Fig 5: Disconnecting Heated Oxygen Sensor (HO2S) G39 Harness Connector

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-- Remove the plenum chamber bulkhead. Refer to Description and Operation .

-- Disconnect the electrical connectors from the ignition coils and set the wiring harness aside.

Fig 6: Disconnect Connectors Of Ignition Coils

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

Fig 7: Disconnecting Coolant Line To Coolant Expansion Tank

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

Fig 8: Identifying Coolant Hoses

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-- Remove the coolant line bracket bolt -3-.

-- Disconnect the upper coolant hose from the heater core -arrow-.

Fig 9: Disconnecting Upper Coolant Hose From Heater Core

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-- Remove the shield with coolant pipe bolts -arrows-.

Fig 10: Removing Shielding Plate With Coolant Pipe

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-- Remove the crankcase ventilation line heat shield bolts -1- from the turbocharger.

Fig 11: Identifying Crankcase Ventilation With Heat Shield, Crankcase Ventilation From Cylinder Head Cover, Oil Supply Line & EVAP Canister Line

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-- Disconnect the crankcase ventilation line from the cylinder head cover -2- and remove it.

-- Disconnect the connecting hose -3- from the turbocharger to the cylinder head cover.

-- Remove the oil supply line banjo bolt -4- from the turbocharger.

-- Remove both upper nuts -arrows- of the front exhaust pipe/turbocharger.

Fig 12: Identifying Both Upper Mounting Nuts Of Front Exhaust Pipe/Turbocharger

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

Fig 13: Installing Protective Cap For Drive Axle On Engine

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-- Remove both lower nuts -arrows- of the front exhaust pipe/turbocharger.

Fig 14: Identifying Both Upper Mounting Nuts Of Front Exhaust Pipe/Turbocharger

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-- Remove the exhaust system suspended mount bolts -arrows-.

Fig 15: Identifying Bracket For Exhaust System

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-- Loosen the clamping sleeve nuts -arrows- and remove the exhaust system.

Fig 16: Disconnecting Exhaust System At Clamping Sleeve

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-- Disconnect the front exhaust pipe from the turbocharger and slide it toward the rear slightly.

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

Fig 17: Identifying Oil Supply Line And Coolant Supply Line At Turbocharger

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-- Remove the oil return line bolts -arrows- from the turbocharger.

Fig 18: Identifying Oil Return Line

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

Fig 19: Identifying Bolts And Support For Turbocharger

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

Fig 20: Identifying Pendulum Support & Bolts

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-- Pull the engine approximately 20 mm toward the rear using the T10038.

Fig 21: Pulling Engine Toward Rear Using Tensioning Strap T10038

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-- Disconnect the coolant pipe -arrow-.

Fig 22: Disconnecting Coolant Pipe

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-- Remove the coolant pipe bracket bolt -1-.

Fig 23: Removing Bolt For Coolant Pipe And Top Nuts

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-- Remove the exhaust manifold/turbocharger upper nuts -arrows-.

-- Remove exhaust manifold/turbocharger upward.

Installing 

Installation is performed in reverse order. When doing this note the following:

• Connect the hose connections with connector couplings. Refer to HOSE CONNECTIONS WITH CONNECTOR COUPLINGS .
• Always replace seals, gaskets and self locking nuts.
• Add oil to the turbocharger through the oil supply line hole.
• Coolant return line must be installed together with the turbocharger.
• Hose connections and charge air system hoses must be free of oil and grease before installing. Sealing ring and sealing surfaces on the connector couplings must only be lightly lubricated. Refer to HOSE CONNECTIONS WITH CONNECTOR COUPLINGS .
• Secure all hose connections with hose clamps.
• After installing the turbocharger, let the engine idle for approximately 1 minute to ensure adequate oil supply to the turbocharger.

-- Install the exhaust system and align it free of tension. Refer to EXHAUST SYSTEM, INSTALLING .

-- Fill the cooling system. Refer to DRAINING AND FILLING .

Tightening Specifications