Volkswagen Workshop Service and Repair Manuals

Removing and installing turbocharger Special tools and workshop equipment required

t  Hose clip pliers -VAS 6340- Removing   Note Fit heat shield sleeve in the same place when installing. –  Observe rules for cleanliness → Chapter.   Caution If a mechanical fault is discovered on the turbocharger (e.g. a destroyed compressor impeller), it is not sufficient to just renew the turbocharger. To avoid any subsequent damage, the following work must be carried out: t  Check air filter housing, air filter element and air inlet hoses for contamination. t  Check the whole charge air path and charge air cooler for foreign objects. t  If foreign objects are discovered in the charge air system, clean the charge air path and, if necessary, renew the charge air cooler. –  Remove particulate filter → Chapter. –  Remove air filter housing → Chapter.

–  Remove crankcase breather hose -1- from cylinder head cover. Do this by operating release buttons. –  Expose vacuum hoses -arrows- at air pipe. –  Unscrew bolt -2-, swing air pipe with inlet connection to rear and pull off from turbocharger.

–  Remove heat-shield sleeve. –  Pull vacuum hose -2- from turbocharger vacuum unit. –  Separate vacuum hose -3-. –  Disconnect electrical connector -1- at position sender for charge pressure positioner -G581-.

–  Free electrical connector -3- for exhaust temperature sender 1 -G235- and electrical line.

–  Remove bolts -arrows-. –  Undo hose clip -1- and remove the pulsation damper -2-.

–  Unscrew bolts and remove pipes -A- for exhaust gas recirculation. –  In vehicles with an auxiliary heater, remove the brackets for the coolant lines leading to the auxiliary heater from the cylinder block or transfer gearbox and the oil sump. Front-wheel drive vehicles

–  Unscrew bolts -1, 3-, union nut -2- and banjo bolts -4, 5-, and remove turbocharger support with oil supply line. Vehicles with four-wheel drive –  Remove right drive shaft → Running gear, axles, steering; Rep. gr.40. –  Pull right flange shaft from bevel box → final drive, axle differential; Rep. gr.39.

–  Unscrew hollow bolts -4- and bolts -1- and -3-. –  Open connecting clamp for oil supply line, disconnect and remove support from the oil supply line.

–  Remove oil supply line -2- on turbocharger. Continuation for all vehicles

–  Unscrew bolts -arrows- and remove heat shield.

–  Remove nuts -arrows-. –  Remove turbocharger together with exhaust manifold from cylinder head and turn so that intake side is facing downwards. Remove turbocharger together with exhaust manifold downwards. Installing l  Specified torques → Chapter „Assembly overview - turbocharger“. Installation is carried out in the reverse order; note the following:   Note t  Renew seals, gaskets, O-rings and self-locking nuts. t  Fill turbocharger with engine oil at connection for oil supply line. t  Hose connections and air intake pipes/hoses must be free of oil and grease when installing. t  Secure hose connections with hose clips corresponding to the series equipment → Electronic parts catalogue. t  After installing turbocharger, run engine for about 1 minute at idling speed to ensure that oil is supplied to turbocharger. t  Fit heat shield sleeves in the same place when installing turbocharger. –  Installing intake hoses with screw-type clips → Fig.. –  Install exhaust gas recirculation pipes → Chapter. –  Connect vacuum hoses → Chapter. –  Electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations. –  Install air filter housing → Chapter. –  Install particulate filter → Chapter.