Turbocharger: Service and Repair

Turbocharger, removing and installing (engine code 1Z/AHU)

Note: It is strongly recommended that penetrating oil be applied to all nuts and bolts in the turbo exhaust track prior to attempting removal. Failure to do so may result in seized nuts, and/or broken studs.

WARNING:
Do not re-use fasteners that are worn or deformed in normal use.
Some fasteners are designed to be used only once, and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts, washers, circlips and cotter pins. Always follow recommendations in this manual-replace these fasteners with new parts where indicated, and any other time it is deemed necessary by inspection.

Note: All hose connections are secured with clips. Charge air pressure must be leak free. Replace self-locking nuts.

Observe rules for cleanliness.

Special Tools, Testers And Auxiliary Items

- VAG1331 torque wrench, 5 to 50 Nm
- High temperature (2000°F) anti-seize compound

Removing

- Switch ignition off.

CAUTION: Before disconnecting the battery, determine the correct coding for the anti-theft radio.

- Disconnect battery Ground strap.





- Remove hoses between intake manifold to turbocharger -1- and turbocharger to air cleaner -2-.
- Remove red hose (or remove banjo bolt) for wastegate bypass regulator valve -N75- on turbocharger.
- Disconnect exhaust pipe from turbocharger.
- Disconnect oil supply line from turbocharger and mounting clip from intake manifold.
- Remove turbocharger to engine support.
- Disconnect oil return line at turbocharger.






- Remove nut -1- from below and bolts -2- from above.
- Lift turbocharger out and upward.
- Disconnect blue hose from wastegate.

Installing

- Install blue wastegate hose on turbocharger and secure with clamp.
- Grease threads of mounting bolts -2- and head contacting surfaces with high temperature (2000°F) anti-seize compound.
- Install turbocharger on exhaust manifold and tighten mounting bolts -2- finger-tight.

- Install mounting nut -1- and tighten.
Tightening torque: 20 Nm (15 ft lb).

- Tighten mounting bolts -2-.
Tightening torque: 35 Nm (26 ft lb).

- Install turbocharger to cylinder head support.
Tightening torque: 25 Nm (18 ft lb).

- Install oil return pipe with new seal and tighten.
Tightening torque: 30 Nm (22 ft lb).

- Install front exhaust pipe with new gasket onto flange and tighten.
Tightening torque: 25 Nm (18 ft lb).

- Fill turbocharger with engine oil via oil supply connection.
- Install oil supply line.
Tightening torque: 25 Nm (18 ft lb).

- Tighten oil supply line support to: 10 Nm (7 ft lb).
- Install red hose for wastegate bypass regulator valve -N75- on turbocharger and secure with clamp (or banjo bolt with new seal) and tighten.
Tightening torque: 15 Nm (11 ft lb).

- Install O-ring onto intake pipe, then install pipe to turbocharger and tighten.
Tightening torque: 10 Nm (7 ft lb).

- Install pressure line.

CAUTION: After installing the turbocharger, let engine idle for approx. 1 minute. DO NOT rev-up the engine at first! (This ensures that the turbocharger is properly lubricated).