Turbocharger, Removing and Installing

TURBOCHARGER, REMOVING AND INSTALLING

Special tools, testers and auxiliary items
- 3205 swivel wrench (Engine code AAZ)
- VAG 1331 Torque wrench 5 to 50 Nm (3 to 37 ft lb)
- High temperature (2000 °F) anti-sieze compound

Removing
- Switch OFF ignition
- Disconnect battery Ground strap

CAUTION: Obtain the radio anti-theft code before disconnecting the battery Ground.





- Remove hoses between intake manifold to turbocharger -1- and turbocharger to Air Cleaner -2-
- Pull off 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/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 turbo and secure with a clamp





- Grease mounting bolts -2- threads and head contacting surfaces with high temperature (2000 °F) anti-sieze compound
- Install turbocharger on exhaust manifold and tighten mounting bolts -2- finger-tight
- Install mounting nut -1- and tighten
- 20 Nm (15 ft lb)
- Tighten mounting bolts -2-
- 35 Nm (26 ft lb)
- Install turbocharger/cyl. head support and tighten
- 25 Nm (18 ft lb)
- Install oil return pipe with new seal and tighten
- 30 Nm (22 ft lb)
- Install front exhaust pipe with new gasket onto flange and tighten
- 25 Nm (18 ft lb)
- Fill the turbocharger with engine oil via the oil supply connection
- Install oil supply line and tighten
- 25 Nm (18 ft lb)
- Tighten oil supply line support
- 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
- 15 Nm (11 ft lb)
- Insert O-ring onto intake pipe, then install the pipe on the turbocharger and tighten
- 10 Nm (7 ft lb)
- Install pressure line
- After installing the turbo, idle the engine for approx. 1 minute, do not rev the engine up at first! (to ensure that the turbocharger is properly lubricated)