Turbocharger, Removing and Installing
Turbocharger, Removing and Installing
Special tools, testers and auxiliary items required
• Spring-type clip pliers (VAS 5024 A)
• Socket XZN 10 (T10154)
• Bits (T10099)
• Engine bung set (VAS 6122)
• Torque Wrench (V.A.G 1331)
CAUTION!
If mechanical damage is found on exhaust turbocharger, e.g. 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 insert and the intake hoses for contamination.
• Check entire charge air circuit and cooler for contamination.
If contaminants are found in charge air circuit, circuit must be cleaned and cooler replaced if necessary.
Removing
- Remove the air filter => [ Air Filter, Removing and Installing ] Air Filter, Removing and Installing.
- Remove the battery and battery tray.
- Remove noise insulation => Body Exterior 50 noise insulation.
- Remove the front part of the right wheel housing liner and/or the front right wheel housing liner => Body, Exterior 66 Wheel Housing Liner.
- Drain the coolant => [ Cooling System, Draining and Filling ] Cooling System, Draining and Filling.
- Catalytic Converters with Front Exhaust Pipe, Removing => [ Catalytic Converters with Front Exhaust Pipe, Removing and Installing ] Service and Repair.
- Remove bolts - arrows -.
- Remove the air guide pipe by lifting the clamps - items 1 and 2 -.
Vehicles with all wheel drive:
- Remove the heat shield above the right driveshaft.
All:
- Disconnect electrical connectors - 1 and 2 - and free up electrical wire - arrows -.
Vehicles with auxiliary heater:
- Remove the bolts - 1 and 2 - and swivel the coolant tubs to the left.
Vehicles with front wheel drive:
- Remove the right driveshaft heat shield - arrows -.
All vehicles:
- Remove the bolt - 1 - using Socket XZN 10 (T10154).
- Remove the bolt - 2 -.
- Remove the banjo bolt - 2 - and move the coolant line to the side.
Vehicles with front wheel drive:
- Remove the bolts - 1 - on the oil return line.
Vehicles with all wheel drive:
- Remove the oil return line bolts on the crankcase.
All vehicles:
- Remove the bolt - 3 - on the oil supply line.
- Remove engine cover.
- Disconnect the connectors from the ignition coils and the wiring harness and lay them aside.
- Disconnect the coolant line to the coolant reservoir - arrow -.
- 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 (GND) - 3 - and remove the bolt - 4 -.
Engine codes BZB, CAWA, CAWB and CGYA:
- Press the release buttons, remove the air guide hose - 1 - and move them to the side.
- Remove the air guide pipe bolt - arrow -.
- Remove the air guide pipe; to do this, loosen the hose clamp - 2 -.
Engine codes CBFA, CCTA and CCTB:
- Remove the air guide pipe bolt - arrow -.
- Loose the hose clamp - 2 - and lay the air guide pipe on the cylinder head.
All:
- Seal the turbocharger with the Engine bung set (VAS 6122).
- Remove the bolts - 1 though 3 - and remove the heat shield together with the coolant pipe.
• On 2.0L engines, remove the bolt - 2 - from the heat shield with a 6 mm - A - hex socket. The hex socket must be at least 5 cm - B - long. A socket that is 6 mm at the tip is too wide.
- Disconnect the oil supply line from the turbocharger - 4 -.
- Disconnect the coolant hose - arrow - and move it to the side.
- Remove the nuts - arrows -.
- Remove the turbocharger/exhaust manifold upward.
Installing
CAUTION!
If mechanical damage is found on exhaust turbocharger, e.g. 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 insert and the intake hoses for contamination.
• Check entire charge air circuit and cooler for contamination.
If contaminants are found in charge air circuit, circuit must be cleaned and cooler replaced if necessary.
Installation is performed in the reverse order of removal, noting the following:
• Assembly of hose connections with connection couplings => [ Hose Connections with Connector Couplings, Assembling ] Hose Connections With Connector Couplings, Assembling.
• Always replace seals, gaskets and self-locking nuts.
• Add oil to turbocharger through oil feed line connecting piece.
• After installing turbocharger, let engine idle for approximately 1 minute to ensure adequate oil supply to the turbocharger.
• Coolant return line => [ (Item 5) Coolant return line ] Turbocharger, Assembly Overview must be installed together with turbocharger.
• Hose connections and charge air system hoses must be free of oil and grease before installing. Sealing ring and sealing surfaces must only be lightly oiled with connector couplings => [ Hose Connections with Connector Couplings, Assembling ] Hose Connections With Connector Couplings, Assembling.
• Secure all hose connections using hose clamps appropriate for the model type.
Tightening specifications => [ Turbocharger, Assembly Overview ] Turbocharger, Assembly Overview
1)replace nuts
2) Use hot bolt paste