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 -V.A.G 1331- Removing   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.   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.

–  Lift engine cover panel at points -1- and pull it forwards in direction of -arrow-.

–  Unbolt heat shield over turbocharger -arrows-. –  Open and close expansion tank cap to release pressure in cooling system. –  Drain coolant (Golf Plus, Eos, Scirocco, Golf, Golf Cabriolet, Touran, Polo, Tiguan) → Chapter. –  Drain coolant (Sharan) → Chapter. –  Drain coolant (Passat, Passat CC) → Chapter. –  Depending on vehicle equipment, remove noise insulation or skid plate → General body repairs, exterior; Rep. gr.50. –  Remove radiator fan -V7- together with cowling → Chapter. Continuation for all vehicles   Note Pull coolant hoses off engine with hose clip pliers -VAS 6340-. –  Observe rules for cleanliness → Chapter.

–  Pull off connecting hoses -1- and coolant hoses -3-. –  Unscrew bracket -2- and securing nuts -4- from turbocharger.

–  Unscrew securing bolt -2- and remove upper coolant pipe.   Note The lower coolant pipe can only be removed following the removal of the catalytic converter. –  Unscrew bolts -1- and remove pressure pipe. Passat, Passat CC –  Remove cowling → Chapter. –  Remove catalytic converter → Chapter. –  Continuation for all vehicles

–  Remove wiring for Lambda probe after catalytic converter -G130- and for alternator from cable guides -arrows-. –  Pull connector off Lambda probe after catalytic converter -G130- and remove.

–  Open hose clip -3- and remove charge air pipe -2-. –  Unbolt exhaust pipe from catalytic converter -arrows-.

–  Unbolt exhaust pipe to rear silencer -arrows-.   Note In the Polo, the catalytic converter is removed together with the front exhaust pipe.

–  Loosen securing bolts of clamp -arrows- and pull exhaust pipe to rear. –  Also pull out exhaust pipe together with flexible joint. –  Remove catalytic converter together with charge air pipe downwards. Removing poly V-belt (Tiguan) → Chapter. Remove poly V-belt (Golf Plus, Eos, Scirocco, Golf, Golf Cabriolet, Touran, Polo, Sharan, Passat, Passat CC) → Chapter.

–  Unscrew securing bolts for tensioning element -arrows- and remove it. –  Remove upper alternator bolt and swing alternator out forwards. –  Unscrew securing bolt -arrow- for oil return pipe -2- from turbocharger.

–  Pull oil return pipe downwards. –  Unbolt charge air hose -1- from turbocharger. –  Unscrew banjo bolts of oil supply pipe -arrows- at turbocharger and at valve timing housing.

–  Remove oil supply pipe. –  Unscrew all securing nuts from exhaust manifold -1-. –  Pull exhaust manifold out upwards with turbocharger.   Note The turbocharger can only be renewed together with the exhaust manifold. Installing   Caution Oil supply line must be renewed when installing a new turbocharger. Installation is carried out in the reverse order. When installing, note the following: t  Renew studs and fastening nuts. t  Screw studs into cylinder head until they project only by 25 mm. t  Observe tightening sequence and specified torques: items -A- to -I- → Chapter. 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  Hose connections and hoses for charge air system must be free of oil and grease before assembly. t  Secure all hose connections with hose clips which conform to production standard. t  Install exhaust system and align it free of stress.

t  When installing air pipes with plug-in connector, ensure that securing clip -arrow- audibly engages into retaining lug -A-. Fitting hose connections with plug-in connectors → Chapter Specified torques:   Caution The screw-type clips on the charge air pipes must be tightened to 5.5 Nm. If the torque is too low or too high, the charge air hose may slip off the charge air pipe during vehicle operation. Assembly overview - turbocharger → Chapter. Assembly overview - charge air system (Eos, Golf Plus, Golf, Golf Cabriolet, Touran, Scirocco, Tiguan, Sharan) → Chapter Assembly overview - charge air system (Polo) → Chapter Assembly overview - charge air system (Passat, Passat CC) → Chapter Assembly overview - catalytic converter and add-on parts → Chapter Install alternator → Electrical system; Rep. gr.27.

–  Push engine cover panel down at points -1- in direction of -arrow- until it engages.