Turbocharger: Service and Repair
Removal and Installation
Special Tools
- Turbocharger tester -VAG1397A-
- Scan Tool -VAG1551- or -VAG1552-
- Adapter cable -VAG1551/3
- Vehicle Diagnostic Testing and Information System -VAS 5051-
- Cable with 3 m current supply -VAS5051/1-
- Portable multimeter -VAG1526/A-
- Voltage Tester -VAG1527/B-
- -VAG1594A-
- Adapter cable -VAG1598/31-
- Vehicle Diagnostic Testing and Information System -VAS 5051 with Cable with 3 m current supply -VAS5051/1-
- Charge air system tester -VAG1687-
- Pressure adapter -VAG1687/1-
- Evaporative system leak detector -KLI9210-
Observe rules for cleanliness.
Note
Turbochargers must be replaced in pairs. Manufacturing tolerances may prevent matched operation.
All hose connections are secured with clips.
Charge air system must be free of leaks.
Replace self-locking nuts.
Replace all seals and gaskets
- Remove engine. Engine, Removing
Removing right-hand turbocharger
- Remove cover panel from right-hand cylinder head cover -arrows-.
- Disconnect hose -1-.
- Disconnect hose -2-.
- Unbolt upper section of intake line -3-.
Note: Plug lower section of intake line.
- Remove lower section of intake line -arrow-.
- Push back heat insulation hose in direction of -arrow-.
- Disconnect vacuum hose -1-.
- Unbolt bracket -2- with transmission oil lines.
- Disconnect line -3-.
- Disconnect pressure hose -4- from turbocharger.
- Disconnect oil return line -1-.
- Disconnect water line -2-.
- Disconnect hose -arrow- from cylinder head.
- Remove turbocharger -arrows-.
Installing
- Install in reverse sequence.
Note: When installing turbocharger, make sure that O-ring for oil returnis not damaged.
Removing left-hand turbocharger
- Push back heat insulation hose in direction of -arrow-.
- Disconnect vacuum hose -1-.
- Remove lower section of pressure line -2-.
- Disconnect pressure hose -3- from turbocharger.
- Disconnect vacuum line -1-.
- Disconnect vacuum hose -2-.
- Disconnect line -3- going to right-hand turbocharger.
- Disconnect oil return line -1-.
- Disconnect water line -2-.
- Remove turbocharger -3- (3 bolts).
Installing
- Installation is the reverse of removal.
Note: When installing turbocharger, be sure that o-ring at connection flange for oil return is not damaged.
The text Abgasturbocharger must be readable as shown in illustration, install turbocharger hose -1- properly if necessary.
The hose clamps -2- must be installed as shown in illustration.
The bolt locks on the screw clamps must be placed at the X-marking on the hose.
Tightening torque
- Turbocharger 20 Nm
- Intake line to cylinder head 10 Nm
- Heat shield to turbocharger 10 Nm
- Exhaust manifold to exhaust pipe 25 Nm
- Injector pipes 30 Nm
- Intake pipe to engine support 10 Nm
- Oil pipe to turbocharger 15 Nm
- Oil pipe to intake manifold 20 Nm