Turbocharger

Turbocharger

Special tools, testers and auxiliary items required

• Hose Clip Pliers (V.A.G 1921)

• Hose Clip Pliers (VAS 6340)

Removing

- Remove the engine cover - arrows -.






- Disconnect the connector - 1 - from the Mass Airflow (MAF) sensor (G70).






- Loosen the air intake hose - 2 -.

- Remove the air filter housing upward - arrows -.

- Disconnect the coolant hose - arrow -.






• The engine is not shown in the illustrations that follow.

- Remove the heat shield - arrows -.






- Remove the crankcase housing ventilation - arrows - from the turbocharger.






- Remove the hose - 1 - from the turbocharger.

- Remove the bolts - 1 and 2 - and move the oil supply line to the side.






- Remove the bolt - 3 - and move the coolant line to the side.

- Loosen the hose clamp - arrow -, pull off the air guide hose and move it to the side.






- Disconnect the connectors - 1 and 2 - and free up the wire.






- Remove the bolts - arrows - on the oil return line.













The decoupling elements in the front muffler could be damaged.

• Do not bend decoupling elements in front muffler more than 10°.

- Loosen the threaded connections - arrows - and slide the clamping sleeves to the rear.

- Slightly lower the front muffler and tie it to the crossbrace - arrow -.






- Disconnect the threaded connection - 1 -, remove the bolt - 2 - and remove the catalytic converter mounting.






- Remove the nuts - arrows - and push the catalytic converter to the rear.






- Remove the right engine mount. Refer to => [ Engine Mount ] Service and Repair.

- Disconnect the wire - 1 - from the right engine support.






- Remove the right engine support - arrows -.

- Remove the bolts - arrows - and then remove the turbocharger support.






- Remove the nuts - arrows -.






- Remove the turbocharger with the exhaust manifold upward.

Installing

Install in reverse order of removal. Note the following:

• Tightening specifications, refer to => [ Turbocharger Overview ] Turbocharger Overview.

• Replace the seals, O-rings and the self-locking nuts.

• Fill the turbocharger with engine oil at the oil supply line connection.

• Hose connections and charge air system hoses must be free of oil and grease before installing.

• Secure all hose connections with hose clamps of the same type as those equipped by the factory. Refer to the Parts Catalog.

- Install the right engine mount. Refer to => [ Engine Mount ] Service and Repair.

- Install the catalytic converter. Refer to => [ Catalytic Converter ] Catalytic Converter.

- Install exhaust system free of stress. Refer to => [ Exhaust System, Aligning ] Exhaust System, Aligning.

- Air guides, installing with connector. Refer to => [ Air Ducts with Connector Couplings ] Air Ducts With Connector Couplings

- Fill with coolant => [ Filling ] Service and Repair.

- Check the oil level.

• After installing turbocharger, let engine idle for approximately 1 minute without increasing engine speed. This ensures adequate oil supply to the turbocharger.