Turbocharger Overview
Turbocharger Overview
• Secure all hose connections using hose clamps appropriate for the model type.
• Hose connections and charge air system hoses must be free of oil and grease before installing. On connector couplings, the seal and sealing surfaces must only be lightly oiled. Refer to => [ Hose Connections with Connector Couplings, Assembling ] Service and Repair.
• Charge air system must be properly sealed.
• Replace the self-locking nuts.
• Hose clip pliers (VAS 6362) or hose clip pliers (V.A.G 1921) are recommended for installing spring clamps.
• Add oil to turbocharger through oil feed line connecting piece.
• After installing turbocharger, let engine idle for approximately 1 minute without increasing engine speed. This ensures adequate oil supply to the turbocharger.
• Pay attention to the rules of cleanliness. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
Part I
1 Turbocharger
• Can only be replaced with exhaust manifold and pressure unit.
• Removing and installing, refer to => [ Turbocharger Vacuum Diaphragm, Checking ] Turbocharger Vacuum Diaphragm, Checking
2 To the Evaporative Emission (EVAP) Canister
3 Turbocharger Vacuum Diaphragm
• Checking, refer to => [ Turbocharger Vacuum Diaphragm, Checking ] Turbocharger Vacuum Diaphragm, Checking
• Removing and installing, refer to => [ Turbocharger Vacuum Diaphragm ] Service and Repair
• Adjusting, refer to => [ Turbocharger Vacuum Diaphragm, Adjusting ] Turbocharger Vacuum Diaphragm, Adjusting
4 Hose
5 Hose
6 Bolt
• 3 Nm
7 Wastegate Bypass Regulator Valve (N75)
8 Hose
9 Connection
10 Clip
11 Bolt
• 9 Nm
12 Seal
• Replace
13 Turbocharger Recirculation Valve (N249)
• Note the installation position
14 Bolt
• 7 Nm
15 Seal
• Replace
Turbocharger Recirculation Valve (N249) Installed Position
- Note installation location - arrows -.
Part II
1 Seal
• Replace
2 Bolt
• 30 Nm
3 Oil Supply Line
4 Turbocharger
• Can only be replaced with exhaust manifold and pressure unit.
• Removing and installing, refer to => [ Turbocharger ] Turbocharger
5 Bolt
• 9 Nm
6 Bolt
• 9 Nm
7 Seal
• Replace
8 Bolt
• 35 Nm
9 Bolt
• 9 Nm
10 Bolt
• 35 Nm
11 Seal
• Replace
12 Coolant Supply Line
13 O-ring
• Replace
14 Bolt
• 9 Nm
15 Seal
• Replace
16 Oil Return Line
17 Bolt
• 9 Nm
18 Seal
• Replace
Part III
1 Seal
• Replace
2 Nut
• Replace
• Coat the exhaust manifold stud bolts with hot bolt paste; hot bolt paste, refer to the Parts Catalog.
3 Bolt
• 35 Nm
4 Seal
• Replace
5 Coolant Supply Line
6 Bolt
• 9 Nm
7 Turbocharger
• Can only be replaced with exhaust manifold and pressure unit.
• Removing and installing, refer to => [ Turbocharger ] Turbocharger
8 Bracket
9 Bolt
• 30 Nm
• Coat the bolt with hot bolt paste; hot bolt paste, refer to the Parts Catalog.
10 Bolt
• 30 Nm
• Coat the bolt with hot bolt paste; hot bolt paste, refer to the Parts Catalog.
11 Nut
• 30 Nm
• Replace
• Do not open when removing turbocharger
• Coat the exhaust manifold stud bolts with hot bolt past; hot bolt paste, refer to the Parts Catalog.
12 Clamping Strip
Turbocharger - Tightening Sequence
- Tighten the nuts - 1 through 5 - in 4 steps as follows:
- 1. Tighten down nuts using 5 Nm.
- 2. Tighten down nuts using 12 Nm.
- 3. Tighten down nuts using 16 Nm.
- 4. Tighten down nuts using 25 Nm.
Part IV
1 Turbocharger
• Can only be replaced with exhaust manifold and pressure unit.
• Removing and installing, refer to => [ Turbocharger ] Turbocharger
2 Turbocharger Vacuum Diaphragm
• Checking, refer to => [ Turbocharger Vacuum Diaphragm, Checking ] Turbocharger Vacuum Diaphragm, Checking
• Removing and installing, refer to => [ Turbocharger Vacuum Diaphragm ] Service and Repair
• Adjusting, refer to => [ Turbocharger Vacuum Diaphragm, Adjusting ] Turbocharger Vacuum Diaphragm, Adjusting
3 Bolt
• 10 Nm
4 Nut
• 9 Nm
• Secure with sealing wax; sealing wax, refer to the Parts Catalog.
5 Locking Plate
6 Knurled Nut
Additional Tightening Specifications
