Charge Air System With Turbocharger
Charge air system and turbocharger
Observe rules for cleanliness
Notes: All hose connections are secured with clips.
The use of VAG 1921 spring clip pliers is recommended
Turbocharger system must be leak free.
Replace self-locking nuts.
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
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 exhaust manifold from cylinder head and remove exhaust manifold and turbocharger as an assembly.
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 exhaust manifold/turbocharger assembly, remove any remaining gasket material and ensure that mounting surfaces are 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 system components, removing and installing
1. Exhaust manifold
Part of turbocharger
Only replace as assembly
2. Intake manifold
3. From charge air cooler
4. Gasket
Always replace
Coating (beading) toward intake manifold
5. 25 Nm (18 ft. lbs.)
6. Gasket
Note installation position
7. Bracket
For heat shield (item 9)
8. Washer
9. Heat shield
Engage in bracket (item - 7 -)
10. Turbocharger
Only replace as assembly
Removing: remove right drive shaft at transmission:
Before connecting the oil supply line (item- 18-), fill turbocharger with engine oil at supply line connection.
After installation of the turbocharger, run engine at idle for about 1 minute and do not immediately increase engine speed to first assure oil supply to the turbocharger.
Charge air pressure control, checking, refer to Testing and Inspection - Procedures Testing and Inspection
11. Pressure unit
Integral part of turbocharger; cannot be replaced
Charge air pressure control, checking Testing and Inspection
12. Connecting hose
Check for proper fit.
From air cleaner
13. Gasket
Always replace
14. O-ring
Always replace
15. Oil return line
To cylinder block
16. Banjo bolt 40 Nm (30 ft lbs)
17. 15 Nm (11 ft lbs)
18. 40 Nm (30 ft lbs)
19. Bracket
20. 25 Nm (18 ft lbs)
21. Exhaust pipe, front
22. Connection
23. 10 Nm (7 ft lbs)
24. Oil supply line
From oil filter bracket