Volkswagen Workshop Service and Repair Manuals

Removing and installing turbocharger Special tools and workshop equipment required

t  Hose clip pliers -VAS 6340-

t  Torque wrench (5…50 Nm) -V.A.G 1331-

t  Hose clamps up to 25 mm -3094-   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. Removing   Note Before carrying out further work, disconnect battery earth strap. Check whether a coded radio is fitted. Obtain anti-theft coding first if necessary. –  Disconnect battery → Electrical system; Rep. gr.27. –  Clamp off coolant hoses to turbocharger using hose clamps from -3094-.

–  Remove securing bolts -1- from engine cover panel. –  Detach coolant hoses -2- at engine cover panel and pull engine cover panel upwards.

–  Pull connector -1- off turbocharger air recirculation valve -N249-. –  Detach hoses -2- at pressure pipe and open wiring guide -3-.

–  Pull hoses -1- off intake connecting pipe for turbocharger. –  Pull connector -2- off charge air pressure sender -G31- with intake air temperature sender 2 -G299- and remove securing bolts -3-.

–  Press retaining clips -1- outwards and pull pressure pipe -2- upwards. –  Then pull pressure pipe -2- off turbocharger.

–  Unscrew securing bolts -arrows- and remove heat shield from turbocharger.

–  Detach coolant hoses -1- from coolant pipes. –  Unscrew securing bolts -2- and remove coolant pipe -3-. –  Remove poly V-belt → Chapter. –  Remove air conditioner compressor → Heating, air conditioning; Rep. gr.87   Note The air conditioning system lines must not be opened. –  Secure air conditioner compressor to lock carrier. –  Ensure that lines are not kinked.

–  Unbolt securing nuts at turbocharger -arrows-. –  Unclip wiring -1- from catalytic converter.

–  Disconnect connectors -2-. –  Unscrew securing nuts -3- and remove seal. –  Remove catalytic converter downwards.

–  Remove securing bolts -arrows- from heat shield and pull shield off exhaust manifold in direction of -arrow-. –  Remove securing bolts -1- for oil supply pipe -3-.

–  Unscrew banjo bolt -2- from cylinder block and remove oil supply pipe.   Note Beginning with model year 2009 ► banjo bolt -2- is secured on timing housing. –  Unscrew securing bolt -4- and remove bracket -5-.

–  Unscrew securing bolts -1- for oil return pipe -2- and remove pipe.   Note The alternator must only be loosened if the securing nuts have inner drive splines. –  Loosen alternator → Electrical system; Rep. gr.27.

–  Remove all securing nuts -1- from exhaust manifold and pull bracket -3- off studs. –  Remove exhaust manifold together with turbocharger -2- from cylinder head. Installing –  Fit turbocharger together with exhaust manifold and new gasket to cylinder head.

–  Tighten securing nuts to 16 Nm in sequence as specified. Perform further installation in reverse order, paying attention to the following: t  Renew seals, gaskets and self-locking nuts. t  Fill turbocharger with engine oil at oil supply line connection. t  After installing turbocharger, run engine for about 1 minute at idling speed to ensure that oil is supplied to turbocharger. t  Secure all hose connections with hose clips which conform to production standard. Specified torques: Assembly overview - part I, turbocharger → Chapter. Assembly overview - part II, turbocharger → Chapter. Assembly overview - catalytic converter and add-on parts → Chapter –  Top up coolant if necessary → Chapter.

–  Attach coolant hoses -2- to engine cover panel and press engine cover panel downwards. –  Tighten securing bolts -1- for engine cover panel to 8 Nm.