Removal And Installation: Turbocharger: Removing

WARNING: This page is about a different car, the 2015 Volkswagen Beetle, 2014 Volkswagen Beetle, and 2013 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

When installing, install all heat shield boots back in the same positions.

Seal any openings in the turbocharger with the Engine Bung Set VAS 6122.

Various hose connections are secured.

Charge air system must be properly sealed.

Replace the self-locking nuts.

Before screwing on oil supply line, fill turbocharger with engine oil at filler tube.

After installing turbocharger, let engine idle for approximately 1 minute to ensure adequate oil supply to the turbocharger.

-- Follow the guidelines for clean working conditions. Refer to CLEAN WORKING CONDITIONS .

CAUTION:

If mechanical damage (such as a destroyed compression wheel) is found on the turbocharger, just replacing the turbocharger is not enough. To avoid damage later, perform the following steps:

Check the air filter housing, air filter element and air guide hoses for contamination.
Check the entire charge air circuit and charge air cooler for foreign objects.
If there are foreign objects in the charge air system, clean the charge air circuit and replace the charge air cooler if necessary.

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

-- Remove exhaust gas temperature sensor 1 -G235-.

-- Remove the control line between the EGR housing and Exhaust Pressure Sensor 2 -G451- EXHAUST GAS RECIRCULATION OVERVIEW => List Item:Control wire .

-- Remove the housing and EGR cooler. Refer to EXHAUST GAS RECIRCULATION OVERVIEW .

-- Remove the particulate filter with NOx reduction catalytic converter. Refer to PARTICULATE FILTER WITH NOX ABSORPTION CATALYTIC CONVERTER .

-- Disconnect the connector from the Charge Pressure Actuator Position Sensor -G581- -2- on the turbocharger vacuum diaphragm.

Fig 1: Connect The Connector -2-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the vacuum hose -3- on the vacuum diaphragm from the turbocharger.

-- Disconnect the >>black<< connector from Exhaust Gas Temperature Sensor 1 -G235- -2- on the plenum chamber bulkhead.

Fig 2: Disconnect The Black

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Guide the wire out of the retainers on the plenum chamber bulkhead and on the turbocharger.

-- Remove the connecting tube TURBOCHARGER OVERVIEW => List Item:Connecting Pipe.

-- Remove the oil supply line. Refer to OIL SUPPLY LINE TO TURBOCHARGER .

-- Remove the banjo bolt TURBOCHARGER OVERVIEW => List Item:Banjo Bolt from the turbocharger support.

-- Remove the stud bolt TURBOCHARGER OVERVIEW => List Item:Hex Stud from the support on the turbocharger.

-- Turn the lower section of the support 90° and then pull the support downward and off the upper section.

-- Remove the heat shield TURBOCHARGER OVERVIEW => List Item:Heat Shield from the exhaust manifold.

-- Remove the nuts TURBOCHARGER OVERVIEW => List Item:Nut from the exhaust manifold.

-- Remove the turbocharger and exhaust manifold from the cylinder head.

-- Turn the turbocharger so that the intake side faces down and then remove the turbocharger and exhaust manifold downward.