Turbocharger
Turbocharger
Special tools, testers and auxiliary items required
• Hose Clip Pliers (V.A.G 1921)
• Hose Clip Pliers (VAS 6340)
• Engine Bung Set (VAS 6122)
If mechanical damage is found on exhaust turbocharger, for example a destroyed compression wheel, it is not enough to just replace the turbocharger. Perform the following steps to prevent subsequent damage.
• Check the air filter housing, the air filter insert and the intake hoses for contamination.
• Check entire charge air circuit and cooler for contamination.
If contaminants are found in the charge air circuit, the circuit must be cleaned and cooler replaced if necessary.
Removing
• During installation, cable ties must be installed at the same location.
- Remove the engine cover - arrows -.
- Remove the cover for the air guide; to do this, disengage the side clips - arrows -.
- Unclip the lower air guide, to do this, disengage the clips - arrows -.
- Remove both the lower air guide and the air guide hose.
- Disconnect the connector - 1 - from the Mass Airflow (MAF) sensor (G70).
- Remove the air guide hose - 2 -.
- Remove the bolt - 4 - and the air filter housing.
• Ignore - 3 -.
- Remove front exhaust pipe with catalytic converter. Refer to => [ Front Exhaust Pipe with Catalytic Converter ] Service and Repair.
- Remove the right front wheel.
- Remove the noise insulation.
- Loosen the fasteners - 1, 2 and 3 - and remove the right noise insulation.
Cabriolet
- Remove the frame for the noise insulation.
All
- Drain the coolant. Refer to => [ Coolant, Draining and Filling ] Service and Repair.
- Remove the bolts - arrows -.
- Lift the clamps - 1 and 2 - and remove the air guide pipe.
- Disconnect the connectors - 1 and 2 - and free up the wire - arrows -.
- Remove bolts - 1 and 2 - and remove the turbocharger support.
- Remove the banjo bolt - 2 - and move the coolant line to the side.
- Remove the bolts - 1 - on the oil return line.
- Remove the bolt - 3 - on the oil supply line.
• The installation location is shown with the engine removed.
- Press the release buttons, remove the air guide hose - 2 - and move them to the side.
- Remove the air guide pipe bolts - arrows -.
Risk of violating emissions legislation.
• Do not open hose connection - 1 -!
- Lay aside the air guide pipe with the connected crankcase ventilation hose - 1 -. To do this, loosen the hose clamp - 3 -.
- Disconnect the oil supply line from the turbocharger - 1 -.
- Remove the coolant hoses - 4 and 5 -.
- Remove Ground (GND) wire - 2 -.
- Remove the Evaporative Emission (EVAP) canister with the connected lines upward out of the bracket - arrow - and lay it aside.
- Disconnect the coolant hose - arrow -.
- Remove the nuts - arrows -.
- Remove the turbocharger with the exhaust manifold upward.
Installing
• Tightening specifications, refer to => [ Turbocharger Overview ] Turbocharger Overview.
Install in reverse order of removal. Note the following:
• 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.
- Install the turbocharger and exhaust manifold; tightening sequence. Refer to => [ Turbocharger - Tightening Sequence ] Turbocharger Overview.
- Install the front coolant pipes. Refer to => [ Front Coolant Pipes ] Front Coolant Pipes.
- Installing front exhaust pipe with catalytic converter. Refer to => [ Front Exhaust Pipe with Catalytic Converter ] Service and Repair.
- Install exhaust system free of stress. Refer to => [ Exhaust System, Aligning ] Procedures.
- Air guides, installing with connector. Refer to => [ Hose Connections with Connector Couplings, Assembling ] Service and Repair
- Fill with coolant => [ Filling ] Service and Repair.
- Check oil level.
• After installing turbocharger, let engine idle for approximately 1 minute without increasing engine speed. This ensures adequate oil supply to the turbocharger.