Turbocharger, Removing And Installing: Removing

WARNING: This page is about a different car, the 2015 Volkswagen Golf. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

During installation, all heat shield boots must be installed at the same location.

CAUTION:

Danger of malfunction caused by debris.

Refer to GUIDELINES FOR CLEAN WORKING CONDITIONS

-- Remove the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

-- Drain the coolant. Refer to DRAIN THE COOLANT .

-- Remove the front exhaust pipe. Refer to FRONT EXHAUST PIPE, REMOVING AND INSTALLING .

-- Remove the rear coolant pipe. Refer to REAR COOLANT PIPE, REMOVING AND INSTALLING .

-- Remove the left coolant pipes. Refer to LEFT COOLANT PIPES, REMOVING AND INSTALLING .

Vehicle with Exhaust Pressure Sensor 1 -G450- and Differential Pressure Sensor -G505- :

-- Open the heat shield boot -1-.

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-- Remove the connector -5- from the bracket and then release and remove it.

-- Free up the wire.

-- Disconnect the connectors -3, 4 and 6- and free up the wiring harness.

-- Remove the bolt -2- and place the bracket with the differential pressure sensors toward the rear.

-- Release and remove the connectors from the bulkhead. Loosen the cable from the retainers and place over the engine. Refer to COMPONENT LOCATION OVERVIEW - ELECTRICAL CONNECTORS .

Vehicles with Differential Pressure Sensor -G505- :

-- Open the heat shield boot -1-.

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-- Remove the connector -4- from the bracket and then release and remove it.

-- Free up the wire.

-- Disconnect the connectors -3 and 5- and free up the wiring harness.

-- Remove the bolt -2- and place the bracket with the Differential Pressure Sensor -G505- toward the rear.

-- Free up the connectors and wires from the bulkhead.

-- Release and remove the connectors at the bulkhead and place them over the engine. Refer to COMPONENT LOCATION OVERVIEW - ELECTRICAL CONNECTORS .

-- Remove the connection on the turbocharger. Refer to TURBOCHARGER CONNECTIONS, REMOVING AND INSTALLING .

-- Remove the bolts -arrows- and remove the resonator -1-.

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-- Loosen the hose clamp -1- and remove the coolant hose.

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-- Loosen the bolt -2-, remove the bolt -3- and pivot the coolant line to the side.

-- Push the heat shield boot aside and disconnect the connector -5-.

Fig 1: Loosening Sequence For Turbocharger System

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-- Loosen the hose clamp -3- and remove the air duct hose.

-- Loosen the hose clamp -4- and remove the coolant hose.

-- Remove the bolt -1- with the :T10501 and loosen the bolt -2-.

-- Loosen the bolt -1- and remove the screw-type clamp.

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CAUTION:

Pay attention to the wire for the Exhaust Gas Temperature Sensor 1 -G235- -1- when removing the emissions control module!

-- Remove the bolts -arrows- and push the emissions control module and EGR cooler toward the rear.

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-- Remove the bolt -2- and union nut -4-.

-- Remove the bolts -3 and 5- and the oil return line.

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-- Remove the bolts -1 to 4- and remove the diesel particulate filter bracket.

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-- Remove the bolts -arrows- and remove the heat shield -1-.

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-- Remove the vacuum hose -2- from the turbocharger vacuum diaphragm.

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-- Remove the nuts -arrows- and remove the turbocharger with the exhaust manifold from the cylinder head upward.

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