Removing and installing turbocharger, "“biturbo engine”", vehicles with four-wheel drive — AUDI

🧭 Before you start

Remove the bevel box, connecting pipe and catalytic converter, then the right drive shaft, front propshaft tube, gearbox carrier, catalyst bracket, rear torque reaction support and heat shield. Disconnect oil supply and return, vacuum hose and G584, undo the turbo nuts and lift it out rearwards via the subframe. Refit with new seals, gaskets and self-locking nuts, correct repair set, new double seals on banjo connections, and the specified tightening sequence.

Fits: VW Transporter T6 (7F), VW Transporter T6 (7E)

• Renewed: turbocharger, seals

Don't miss

• After a mechanical turbo failure, check the air filter, intake hoses and charge air path for foreign objects.
• Do not kink the oil supply line, and check it for damage after removal and installation.
• Never carry the turbocharger by its control rod; bent linkage impairs turbo function.
• Seal open connections immediately with bungs once lines are removed.
• Note the different bolt lengths at the propshaft intermediate bearing.
• Renew seals, gaskets and self-locking nuts and observe the turbo tightening sequence.

Written for this job from the workshop steps below · TorqFix editorial.

🔧 Engine codes this applies to

📐 31 workshop diagrams for CFCA

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. ⚠ When a mechanical fault is found on the turbocharger, e.g. a destroyed compressor impeller, it is not only sufficient to renew the turbocharger. To avoid subsequent damage, the following work must be carried out:Check air filter container, air filter element and intake hoses for dirt.Check the whole charge air path and charge air cooler for foreign objects.If foreign objects are found in the charge air system, the charged air routing must be cleaned and the charge air cooler must be renewed, if necessary. — Remove bevel box 34Bevel box; Removing bevel box. [Note: After lines and hoses have been removed, the open connections are to be sealed immediately with a plug from the engine bung setVAS 6122.Only use clean plugs.]
2. Remove connecting pipe
3. Release and detach connector (arrow) of exhaust temperature sender 1G235. Then, lay wiring harness to one side.
4. Unscrew bolt (2) and remove from clamp (1).
5. Loosen catalytic converter (3).

6. Unscrew nuts (arrows) above and to right of turbocharger.
7. Unscrew nuts (arrows) above and to left of turbocharger.
8. Pull lines (2), (3) and (4) out of mounting for intake hose (1).
9. Open screw-type clip (5) wide enough to enable removal of intake hose (1).
10. Remove catalytic converter .
11. Remove complete right-hand drive shaft Running gear, axles, steering40.
12. Remove front propshaft tube 39Final drive; Assembly overview - final drive.
13. Unscrew bolts (1) and (2) and remove gearbox carrier (3) from rear torque reaction support and bevel box.
14. Unscrew bolts (1) and remove catalytic converter bracket (2).
15. Unscrew bolt (1) from support mounting (3).
16. Unscrew bolts (2) and bolt (3) and remove rear torque reaction support (1).
17. Unscrew nuts for heat shield (arrow).
18. Unscrew bolts (arrows) from front intermediate bearing and hold propshaft by hand. At the same time, a 2nd mechanic removes the heat shield.
19. Bolt intermediate bearing on loosely. [Note: Note different bolt lengths.]
20. Unscrew bolt (2) of oil supply line (3).
21. ⚠ Oil supply line (3) must not be kinked when removing and installing.Oil supply line (3) must be checked for damage after removing.Notes on checking . — Unscrew bolt (4) and use a cloth to soak up any escaping oil.
22. Remove all lines/wires at the bracket (arrow). Then remove bracket from subframe.
23. Pull hose (1) off vacuum unit (2).
24. Release connector (1) and pull off from regulating flap potentiometer G584.
25. Pull hose (2) off regulating flap potentiometer G584(3).
26. Unscrew nuts (arrows) below and to the right of the turbocharger.
27. Unscrew nuts (arrows) below and to the left of the turbocharger.
28. Unscrew union nut (4) of oil return line (3). When doing this, counterhold on connection (5).
29. Remove bolt (1) from bracket (2).
30. ⚠ Avoid damage to oil supply line . Observe notes.When doing this, ensure that no pressure is exerted on the linkage.Do not hold onto the rod when removing the turbocharger.When carrying the turbocharger, always hold it by the pipes and not by the rod.Bent linkage will impair the function of the turbocharger. — Remove turbocharger, tip towards the rear and remove via the subframe.
31. Cover anti-roll bar with a cloth or similar to avoid damage to paintwork.
32. Guide turbocharger (1) with left-hand side first over gearbox and tachograph connection (3). Then, guide turbocharger (1) over mounting (2) on bevel box.
33. Once turbocharger has been removed, bolt (2) must be released from bracket (1) for reinstalling.
34. Renew seals, gaskets and self-locking nuts.
35. Clean sealing surfaces.
36. When turbocharger and connecting pipes are being assembled, it is essential that the correct repair set Electronic Parts Catalogue is used.
37. Fit new double seal (2) onto the respective line connection (1) and secure by screwing in the corresponding banjo bolt (3).
38. Only screw bolt (1) loosely into bracket (2).
39. ⚠ Note tightening sequence and procedure when bolting turbocharger on .Oil supply line (3) must be checked for damage after installing.Notes on checking . — Install connecting pipes .

Other AUDI procedures

• Removing and installing exhaust manifold gasket – Audi 2.0 TDI
• Removing and installing valve stem seals
• Removing and installing turbocharger, "“biturbo engine”"
• Removing and installing exhaust gas recirculation cooler, "“biturbo engine”"
• Removing and installing sealing flange on pulley end
• Removing and installing toothed belt – Audi · 56 torque figures
• Removing engine – Audi A8 D3 · 41 torque figures
• Removing camshaft timing chain from camshafts – Audi A6/A7 C7 · 38 torque figures
• Installing engine – Audi A8 D4 · 36 torque figures
• Removing and installing camshaft timing chain · 29 torque figures