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 => [ Air Ducts with Connector Couplings ] Air Ducts With Connector Couplings.

• 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

Part II

Part III

Part IV






1 Turbocharger

• Can only be replaced with exhaust manifold and pressure unit.

• Removing and installing, refer to => [ Turbocharger ] Turbocharger

2 Hose

3 Turbocharger Vacuum Diaphragm

• Can be replaced only with the turbocharger

4 Clamp

5 Hose

6 Hose

7 Bolt

• 3 Nm

8 Wastegate Bypass Regulator Valve (N75)

9 Hose

10 Turbocharger Recirculation Valve (N249)

• Note the installation position, refer to => [ Installed Position ]

11 Bolt

• 7 Nm

12 O-ring

• Replace

13 O-ring

• Replace

14 Connection

15 Bolt

• 9 Nm

Turbocharger Recirculation Valve (N249) Installed Position





- Note installation location - arrows -.

Part II

Part I

Part III

Part IV






1 Turbocharger

• Can only be replaced with exhaust manifold and pressure unit.

• Removing and installing, refer to => [ Turbocharger ] Turbocharger

2 Bolt

• 9 Nm

3 Crankcase Ventilation Pipe

4 Seal

• Replace

5 Seal

• Replace

6 Bolt

• 30 Nm

7 Oil Supply Line

8 Bolt

• 9 Nm

9 Bolt

• 9 Nm

10 O-ring

• Replace

11 Seal

• Replace

12 Bolt

• 35 Nm

13 Bolt

• 9 Nm

14 Bolt

• 35 Nm

15 Seal

• Replace

16 Coolant Supply Line

17 Bolt

• 9 Nm

18 Bolt

• 9 Nm

19 Seal

• Replace

20 Oil Return Line

21 Seal

• Replace

Part III

Part I

Part II

Part IV






1 Seal

• Replace

2 Nut

• Replace

• Tightening sequence, refer to => [ Turbocharger - Tightening Sequence ]

• 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 Bolt

• 30 Nm

9 Bracket

10 Support

11 Bolt

• 30 Nm

12 Bolt

• 30 Nm

• Coat the bolt with hot bolt paste; hot bolt paste, refer to the Parts Catalog.

13 Nut

• 30 Nm

• Replace

• Coat the exhaust manifold stud bolts with hot bolt paste; hot bolt paste, refer to the Parts Catalog.

• Do not open when removing turbocharger

14 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

Part I

Part II

Part III






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 ] Adjustments

3 Bolt

• 10 Nm

4 Nut

• 9 Nm

• Secure with sealing wax; sealing wax, refer to the Parts Catalog

5 Locking Plate

• Replace

6 Knurled Nut

Additional Tightening Specifications