Removal And Installation: Turbocharger: Notes

Special Tools And Workshop Equipment Required:

Bits for VAG 1331/13 T10099
Socket - Xzn 10T10154
Torque Wrench 1331 5-50 Nm VAG 1331
Engine Bung Set VAS 6122
Hose Clip Pliers VAS 6340
Hose Clip Pliers VAS 6499

CAUTION:

If mechanical damage is found on the exhaust 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 .

-- Remove the noise insulation, refer to one of the following:

For GTI and Tiguan, 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 REMOVING .

-- 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: Disconnect 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-.

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

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

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-- 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 6 mm Hex Socket -A-, 5 cm 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: Identifying Air Guide Pipe And Bolts

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-- Open the clamps -1 and 2- and remove the air guide pipe.

-- Disconnect the Wastegate Bypass Regulator Valve -N75- from the turbocharger -arrows-.

Fig 9: Identifying Turbocharger And Supports

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

With Front Wheel Drive (FWD)

Fig 10: Identifying Drive Axle Heat Shield Bolts

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

Continuation for All

-- Remove front exhaust pipe with catalytic converter, refer to the following:

For Tiguan, refer to FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER .

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

Fig 11: Identifying Turbocharger Electrical Connectors

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With All Wheel Drive (AWD)

-- Tie the driveshaft up to the left of the tunnel.

-- Remove the right driveshaft. Refer to REMOVAL AND INSTALLATION .

Continuation for All

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

Fig 12: Identifying Turbocharger Support And Bolts

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-- Remove the bolt -2-.

-- Remove the banjo bolt -2- using the Bits for VAG 1331/13 T10099 and set the coolant pipe aside.

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

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

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

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

Fig 14: Identifying Coolant Hose Clamps

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-- Remove the turbocharger nuts -arrows-.

Fig 15: Identifying Turbocharger/Exhaust Manifold Nuts

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-- Remove the turbocharger upward.