Charge Air System With Turbocharger
Charge air system with turbocharger
Notes: All hose connections are secured with clips.
Charge air system must be free of leaks.
Replace self-locking nuts.
Charge air pressure hose and all the respective connections must be free of grease etc. before installing.
Assembly tool VAS 5024 or hose clip pliers V.A.G 1921 are recommended for installing spring-type clips.
Observe rules for cleanliness. Vehicle Damage Warnings
Observe safety precautions. Technician Safety Information
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.
Note: Some vehicles may require the passenger's side drive shaft to be disconnected from the transmission or removed to get required clearance. Refer to Transmission and Drivetrain - Drive Axles, Bearings and Joints - Axle Shaft Assembly - Service and Repair - Procedures Service and Repair
Removal
Remove underbody panels as required to access exhaust and turbocharger
1. Sound insulation: Bolted and inserted into lock carrier in forward area
2. Bolt: Qty. 2
3. Clamping washer: Qty. 4
4. Bolt: Qty. 4
a. Remove airbox assembly with all attached sensors
b. Remove air duct between charge air cooler and intake manifold
c. Remove intake air duct between charge air cooler and turbocharger.
d. Remove oil and coolant lines connected to turbo unit
e. Remove heat shielding, if required for clearance.
f. Disconnect downpipe and catalytic assembly
g. Unbolt turbocharger from exhaust manifold, remove turbo unit.
Installation
- Installation is reverse of removal.
Editor Note: Oil supply lines for turbo along with engine oil and filter should be replaced when installing a replacement turbocharger.
- Prior to reinstalling turbo unit, remove any remaining gasket material and ensure that turbo mounting surface is clean. Reinstall with new gasket.
- Before restarting engine be sure to prime turbo oil supply.
Before starting vehicle, the turbocharger oil drain hose should be disconnected from the oil pan and the engine should be turned over with starter until oil is running out of the oil drain hose. This will ensure that the turbo is lubricated before initial start-up.
Turbocharger With Attachments, Removing And Installing
Part I
1. 40 Nm
Coat threads with G 052 112 A3
2. Seal
3. 10 Nm
Must not be loosened
4. Pressure unit
For charge air pressure regulating valve
Can only be replaced together with turbocharger
Checking charge air pressure control, refer to Testing and Inspection - Procedures Testing and Inspection
5. Circlip
6. Turbocharger
Checking charge air pressure control, refer to Testing and Inspection - Procedures Testing and Inspection
Charge air pressure control valve and charge air pressure control valve vacuum unit are components of the turbocharger and cannot be replaced individually
Fill turbocharger with oil via the connection before connecting the oil supply pipe
After installing turbocharger, let engine idle for approx. 1 minute without increasing engine speed. This ensures adequate oil supply to the turbocharger.
7. O-ring
8. 10 Nm
9. Intake pipe
10. Gasket
Replace
Note installed position
11. 20 Nm
12. Heat shield
13. 10 Nm
14. Banjo bolt, 30 Nm
15. Oil supply pipe
16. 30 Nm
Replace
Coat threads and bolt head contact surface with G 052 112 A3
17. Exhaust manifold
18. Gasket
Replace
Note installed position
19. 20 Nm
20. Banjo bolt, 30 Nm
21. 25 Nm
Replace
Coat threads with G 052 112 A3
22. Banjo bolt, 35 Nm
23. Coolant return pipe
24. 25 Nm
25. Spacer sleeve
26. Banjo bolt, 35 Nm
27. 10 Nm
28. Coolant supply pipe
29. Banjo bolt, 35 Nm
30. 30 Nm
use only original bolts from parts catalog
31. Retainer
Between turbocharger and cylinder block
32. 25 Nm
33. Gasket
Replace
34. Gasket
Replace
35. 10 Nm
36. Oil return pipe
To oil pan
37. 10 Nm
38. 10 Nm
Do Not alter setting
Must not be loosened
Part II
Notes: Components marked with an * are checked by the On Board Diagnostic (OBD).
Components marked with ** are checked by the Output Diagnostic Test Mode.
Observe installed position of heat protection mats
1. Overrun shut-off valve
Checking, refer to Testing and Inspection - Procedures Testing and Inspection
2. Connection pipe/hose
To Recirculating valve for turbocharger -N249- *
3. Pressure regulation valve
For cylinder block housing ventilation
4. Connection pipe/hose
from deceleration shut-off valve to upper air guide pipe
5. to cylinder block housing ventilation
6. From air filter
7. upper air guide pipe
Observe installed position of heat protection mat
Vehicles with engine code AWP, AWW with quick-release connection (with O-ring and securing brace)
Vehicles with engine code AWD with screw-type clamps
8. Bracket
9. 40 Nm
10. 25 Nm
11. For connecting hose of connecting piece/charge air cooler at bottom
12. O-ring
Replace
only vehicles with engine code AWP, AWW
13. Circlip
Check for secure fitting
only vehicles with engine code AWP, AWW
14. 10 Nm
15. from turbocharger/exhaust tube
16. Connection pipe/hose
17. Connection pipe/hose
to pressure unit for charge pressure regulation valve
18. Circlip
Check for secure fitting
19. O-ring
Replace
20. Intake hose
to intake connection of exhaust turbocharger
21. Wastegate Bypass Regulator Valve -N75- */**
Valve is activated (pulsed) by the Engine Control Module (ECM)