Volkswagen Workshop Service and Repair Manuals

Removing and installing turbocharger Special tools and workshop equipment required

t  Spring-type clip pliers -VAS 5024 A-

t  Tensioning strap -T10038-   Caution When mechanical damage is found on the turbocharger, e.g. a destroyed compressor impeller, it is not only sufficient to renew the turbocharger. To prevent this from causing further damage, perform the following repairs: t  Check air filter housing, air filter element and intake hoses for soiling. t  Check complete charged air routing and charge air cooler for foreign objects. If foreign objects are found in the charge air system, the charged air routing must be cleaned and the charge air cooler must be renewed, if necessary. Removing –  Remove engine cover/air filter → Chapter.

–  Remove intake hose by pulling off spring-type clips -1 and 2-. –  Drain coolant → Chapter. –  Remove right wheel housing liner front part or front right wheel housing liner → Rep. gr.66.

–  Pull charge air hose -arrow- from charge air cooler.

–  Unscrew bolts -arrows- and remove charge air pipe.

–  Pull off connectors -1 and 2- and unclip cable. –  Unscrew bolts -arrows- and remove connection from turbocharger.

–  Disconnect connector for Lambda probe -G39--arrow- and lay cable aside.

–  Pull connectors from ignition coils and lay wiring harness to side.

–  Disconnect coolant line to coolant expansion tank -arrow-.

–  Pull off coolant hose -1- and -2-. –  Unscrew coolant line -3-.

–  Pull upper coolant hose from heat exchanger -arrow-.

–  Remove heat shield with coolant pipe -arrows-.

–  Unscrew line for crankcase breather system with heat shield from turbocharger -1-. –  Pull off crankcase breather line from cylinder head cover -2- and remove. –  Pull off activated charcoal filter line to turbocharger from cylinder head cover -3-. –  Release oil supply line at turbocharger -4-.

–  Unscrew both upper securing nuts for front exhaust pipe/turbocharger.

–  Remove heat shield for drive shaft on right side -arrows-.

–  Unscrew both lower securing nuts for front exhaust pipe/turbocharger.

–  Unbolt bracket for exhaust system -arrows-.

–  Disconnect exhaust system from clamping sleeve -arrows-. –  Pull front exhaust pipe from turbocharger and push backwards slightly.   Note The catalytic converter is not removed and the Lambda probe connector is not separated.

–  Unscrew oil supply line and coolant supply line from turbocharger -arrows-.

–  Remove oil return line -arrows- from turbocharger.

–  Unscrew bolts -1- and -2- and remove support for turbocharger.   Note The following procedure is necessary to provide more space between the cylinder head and bulkhead.

–  Remove bolts -2 and 3-.

–  Pull engine back approx. 20 mm with tensioning strap -T10038-.

–  Separate coolant pipe -arrow-.   Note t  The clamping strip nuts need not be loosened. t  Bolt -1- is only fitted on coolant pipes with 2 retainers.

–  Unscrew bolt -1- for coolant pipe and unscrew upper nuts -arrows-. –  Remove turbocharger/exhaust manifold upwards. Installing   Caution When a mechanical fault is found on the turbocharger, e.g. a destroyed compressor impeller, it is not only sufficient to renew the turbocharger. To prevent this from causing further damage, perform the following repairs: t  Check air filter housing, air filter element and intake hoses for soiling. t  Check complete charged air routing and charge air cooler for foreign objects. If foreign objects are found in the charge air system, the charged air routing must be cleaned and the charge air cooler must be renewed, if necessary. Install in reverse order. In the process, note the following: t  Fitting hose connections with plug-in connectors → Chapter t  Renew gaskets, oil seals and self-locking nuts. t  Fill turbocharger with engine oil at connection for oil supply line. t  Install coolant return line → Item together with turbocharger. t  Hose connections and hoses for charge air system must be free of oil and grease before assembly. The oil seals and sealing surfaces must be oiled lightly only for connector couplings → Chapter. t  Secure all hose connections with hose clips comparable to production standard After installing turbocharger, run engine for about 1 minute at idling speed to ensure that oil is supplied to turbocharger. Specified torques → Chapter.

Component		Nm
Pendulum support to gearbox		→ Fig.
Exhaust manifold/turbocharger to cylinder head		201)
Oil supply line to turbocharger		30
Oil return line to turbocharger		9
Coolant supply line to turbocharger		35
Turbocharger bracket to cylinder block		302)
Turbocharger bracket to turbocharger		302)
Air intake pipe (right side) to sump		10

1) Renew nuts. 2) Use high-temperature paste → ETKA (Electronic Parts Catalogue).