Turbocharger
Turbocharger
Special tools, testers and auxiliary items required
• Hose Clip Pliers (VAS 6340)
• Spring Type Clip Pliers (VAS 6499)
• Bit XZN 10 (T10154)
• Bits (T10099)
• Engine Bung Set (VAS 6122)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
If mechanical damage is found on the turbocharger, for example, a destroyed compression wheel, it is not enough to just replace the turbocharger. To prevent subsequent damage, the following work must be performed:
• Check the air filter housing, the air filter element and the intake hoses for contamination.
• Check the entire charge air circuit and charge air cooler for foreign objects.
If contaminants are found in the charge air circuit, the entire circuit must be cleaned and the cooler replaced, if necessary.
Removing
- Remove the air filter housing. Refer to => [ Air Filter Housing ] Air Filter Housing.
GTI and Eos
- Remove the plenum chamber bulkhead.
Continuation for All
- Remove the noise insulation. Refer to one of the following:
GTI and Tiguan
Eos and Passat
CC
- Remove the front part of the right wheel housing liner and/or the right front wheel housing liner..
- Drain the coolant. Refer to => [ Coolant, Draining and Filling ] Procedures.
- Remove the engine cover.
- Disconnect the connectors from the ignition coils and the wiring harness and lay them aside.
- Disconnect the coolant line - arrow - from the coolant expansion tank.
- Disconnect the vacuum line - 1 - at the separating point - 2 - and free up the wire.
- Remove the coolant hoses - arrows - from the coolant pipe.
- Disconnect the ground wire - 3 - and loosen the bolt - 4 -.
- Remove the charge air pipe bolt - arrow -.
- Loose the hose clamp - 2 - and lay the charge air pipe on the cylinder head.
- Seal off the turbocharger using the engine bung set (VAS 6122).
- Remove the bolts - 1 though 3 - and remove the heat shield together with the coolant pipe.
• Remove the bolt - 2 - from the heat shield using a 6 mm - A - hex socket. The hex socket must be at least 5 cm - B - long. A socket that tapers to 6 mm at the tip is too wide.
- Disconnect the oil supply pipe - 4 - from the turbocharger.
- Remove the bolts - arrows -.
- Lift the clamps - 1 and 2 - and remove the charge air pipe.
with All Wheel Drive (AWD)
- Remove the right drive axle heat shield bolts - 1 - and shield - A -.
with Front Wheel Drive (FWD)
- Remove the right drive axle heat shield bolts - arrows - and shield.
Continuation for All
- Remove front exhaust pipe with catalytic converter. Refer to one of the following:
Passat and CC, refer to => [ Front Exhaust Pipe with Catalytic Converter ] Service and Repair.
GTI and Eos, refer to => [ Front Exhaust Pipe with Catalytic Converter ] Service and Repair.
Tiguan, refer to => [ Front Exhaust Pipe with Catalytic Converter ] Service and Repair.
- Disconnect the connectors - 1 and 2 - and free up the wire - arrows -.
- Remove the bolt - 1 - using the bit XZN 10 (T10154).
- Remove the bolt - 2 -.
- Remove the banjo bolt - 2 - using the bit (T10099) and set the coolant pipe aside.
with FWD
- Remove the bolts - 1 - for the oil return pipe.
with AWD
- Remove the oil return pipe bolts from the crankcase.
Continuation for All
- Remove the bolt - 3 - for the oil supply pipe.
- Disconnect the coolant hose - arrow - and move it to the side.
- Remove the nuts - arrows -.
- Remove the turbocharger upward.
Installing
If mechanical damage is found on the turbocharger, for example, a destroyed compression wheel, it is not enough to just replace the turbocharger. Perform the following steps to prevent subsequent damage.
• Check the air filter housing, the air filter element and the intake hoses for contamination.
• Check the entire charge air circuit and cooler for contamination.
If contaminants are found in the charge air circuit, the entire circuit must be cleaned and the cooler replaced as necessary.
Install in the reverse order of removal. Note the following:
• Assembly of hose connections with connection couplings. Refer to => [ Charge Air Hose, Disconnecting and Connecting ] Charge Air Hose, Disconnecting and Connecting.
• Always replace seals, gaskets and self-locking nuts.
• Add oil to turbocharger through oil supply pipe connection on the turbocharger.
• After installing the turbocharger, let the engine idle for approximately 1 minute to ensure adequate oil supply to the turbocharger.
• The coolant return pipe must be installed together with the turbocharger.
• Hose connections and charge air system hoses must be free of oil and grease before installing. For connector couplings, the seal and sealing surfaces must only be lightly oiled. Refer to => [ Charge Air Hose, Disconnecting and Connecting ] Charge Air Hose, Disconnecting and Connecting.
• Secure all hose connections using hose clamps appropriate for the model type.
Tightening Specifications
• 1 Replace nuts
• 2 Use hot bolt paste, refer to the Parts Catalog