Removal And Installation: Turbocharger: Notes

Special tools and workshop equipment required 

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

Removing 

-- Remove the engine cover. Refer to ENGINE COVER .

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

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

-- Remove the right front wheel.

-- Remove the right front rear wheel housing liner. Refer to Removal and Installation .

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

-- Disconnect the connectors -arrows- from the ignition coils with output stages and lay the wiring harness to the side.

Fig 1: Disconnect Connectors Of Ignition Coils

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-- Disconnect the coolant hose -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 remove 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 the turbocharger using plugs from the engine bung set VAS 6122.

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

Fig 5: Identifying Heat Shield Bolts

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NOTE:

Remove the heat shield bolt -2- using a 6 mm hex socket -A-. 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 bolt and the oil supply line from the turbocharger -4-.

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.

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

Fig 9: Identifying Protective Cap For Drive Axle On Engine

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-- Remove the front exhaust pipe with catalytic converter. Refer to FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER .

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

Fig 10: Identifying Turbocharger Electrical Connectors

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

Fig 11: Identifying Turbocharger Support And Bolts

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-- Remove the bolt -2-.

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

Fig 12: Identifying Oil Return Line, Coolant Line And Oil Supply Line Fasteners

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

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

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

Fig 13: Coolant Hose Clamps

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-- Remove the nuts -arrows-.

Fig 14: Identifying Turbocharger/Exhaust Manifold Upper Nuts

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-- Remove the turbocharger upward.