Removal And Installation: Turbocharger

Special tools and workshop equipment required

Hose Clip Pliers VAS 6340
Spring Type Clip Pliers VAS 6499
Bit XZN 10T 10154
Bits T10099
Engine Bung Set VAS 6122
Torque Wrench (5-50 Nm) V.A.G 1331

CAUTION:

If mechanical damage is found on the turbocharger, for example, a destroyed compression wheel, it is not enough to just replace the turbocharger. To prevent subsequent damage, the following work must be performed:

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

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

Removing

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

GTI and Eos

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

Continuation for All

-- Remove the noise insulation. Refer to one of the following:

GTI and Tiguan, refer to Description and Operation

Eos and Passat, refer to "Noise Insulation" in Removal and Installation .

CC, refer to "Noise Insulation" in Description and Operation

-- Remove the front part of the right wheel housing liner and/or the right front wheel housing liner. Refer to Removal and Installation .

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

-- Remove the engine cover.

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

Fig 1: Disconnecting Connectors Of Ignition Coils

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

Fig 2: Disconnecting Coolant Line To Coolant Expansion Tank

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

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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-- Disconnect the oil supply pipe banjo bolt -4- from the turbocharger.

Fig 7: Identifying Heat Shield Bolts

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-- Remove the bolts -arrows-.

Fig 8: Air Guide Pipe And Bolts

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

with All Wheel Drive (AWD)

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

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

with Front Wheel Drive (FWD)

Fig 10: Drive Axle Heat Shield Bolts

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

Continuation for All

-- Remove front exhaust pipe with catalytic converter. Refer to one of the following:

Fig 11: Identifying Turbocharger Electrical Connectors

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Tiguan, refer to FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER .

-- 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 bolt -1- using the bit XZN 10 T10154.

-- Remove the bolt -2-.

-- Remove the banjo bolt -2- using the bit T10099 and set the coolant pipe aside.

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

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with FWD

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

with AWD

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

Continuation for All

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

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

Fig 14: 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:

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 entire circuit must be cleaned and the cooler replaced as necessary.

Install in the reverse order of removal. Note the following:

Assembly of hose connections with connection couplings. Refer to CHARGE AIR HOSE, DISCONNECTING AND CONNECTING .
Always replace seals, gaskets and self-locking nuts.
Add oil to turbocharger through oil supply pipe connection on the turbocharger.
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. For connector couplings, the seal and sealing surfaces must only be lightly oiled. Refer to CHARGE AIR HOSE, DISCONNECTING AND CONNECTING .
Secure all hose connections using hose clamps appropriate for the model type.

Tightening Specifications

Component

Turbocharger to the cylinder head ^{1, 2}

Follow the tightening sequence, refer to Figure

Oil supply pipe to turbocharger (M12 banjo bolt)

Oil return pipe to turbocharger

Coolant supply pipe to turbocharger (tighten banjo bolt M14 using bit T10099)

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,