Removing and installing exhaust turbocharger — VW

ACV AHY AJA AJT AUF AXG AXL AYC
Engine codes ACV, AJT, AUF, AYC

Engine codes AHY, AXG, AXL =>Page
21-24

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

V.A.G 1331 Torque wrench (5...50 Nm)
Grease G 000 500

Removing

With ignition switched off disconnect battery earth strap.

Note:

If necessary the anti-theft coding for the radio must be obtained first.

Removing insulation tray:

=> General body repairs, exterior; Repair group 50; Noise insulation assembly overview.
General body repairs, exterior
Noise insulation assembly overview.

Remove front exhaust pipe => Page
26-1
, Removing and installing parts of exhaust system.
Removing radiator grille:

=> General body repairs, exterior; Repair group 66; Trims
General body repairs, exterior
Trims

Remove charge air cooler bracket -1-.
Remove left and right hand securing bolts -2-.
Fold lock carrier and radiator out forwards -arrow-.
Remove charge air cooler with air hoses
=> Page
21-11
, Removing and installing parts of charge air cooling system.
Pull off control pipe on charge pressure control valve (blue).
Pull off vacuum hoses on connecting pipe (black), exhaust turbocharger (red) and exhaust gas recirculation valve (black).

Remove connecting hose between connecting pipe and air mass meter.
Remove breather hose -1- between crankcase breather valve and connecting pipe.
Remove connecting pipe -2-.
Remove connecting pipe between exhaust gas recirculation valve and exhaust manifold => Page
26-14
, Removing and installing parts of exhaust gas recirculation system.
Remove intake pipe with heat shield and exhaust gas recirculation valve.

Remove oil supply pipe -1- and oil return pipe -2- on turbocharger.

Remove pipe elbow -1-.
Remove securing bolts and securing nuts between exhaust manifold and turbocharger.
Lift turbocharger -2- out, upwards.

Installing

Install in reverse order but note following:

Coat threads and contact surfaces of nuts and bolts which are used between exhaust manifold and turbocharger with grease G 000 500 and tighten to
45 Nm.
Fit pipe elbow to turbocharger and tighten to
25 Nm.
Install oil return pipe with new seal and tighten to
30 Nm.
Fill the turbocharger with engine oil via the oil supply connection.
Install oil supply pipe with new seal and tighten cap nut to
25 Nm.

Fit intake pipe with heat shield and new seal (coating or seal bead points to intake pipe) and tighten to
25 Nm.
Install connecting pipe between exhaust gas recirculation valve and exhaust manifold => Page
26-14
, Removing and installing parts of exhaust gas recirculation system.

Note:

When installing, just nip all bolts (parts must be just free to move), then tighten stress free.

Fit control hose (blue) to exhaust gas recirculation valve and secure with a hose clamp.
Fit vacuum hose (red) to turbocharger and secure with hose clamp.
After installing the turbocharger, run engine for approx. 1 minute at idling speed, do not rev. up immediately. This ensures the turbocharger is properly lubricated.

Engine codes AHY, AXG, AXL

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

T10026 Ring spanner

V.A.G 1331 Torque wrench (5...50 Nm)
Grease G 000 500

Removing

Removing insulation tray:

=> General body repairs, exterior; Repair group 50; Noise insulation assembly overview
General body repairs, exterior
Noise insulation assembly overview

Loosen connecting hoses between air cleaner/turbocharger and turbocharger/charge air cooler on turbocharger.
Disconnect front exhaust pipe on turbocharger
Remove oil filter.

Unscrew oil return pipe -arrow- on oil dip stick guide tube.

Unscrew captive nut of oil supply pipe -1- and the three securing nuts -2- between exhaust manifold and turbocharger.

Unscrew 4th securing nut -arrow- with ring spanner T10026.
Lift turbocharger out upwards.
Guide oil return pipe/hose when doing this.

Installing

Install in reverse order but note following:

Coat threads and contact surfaces of nuts between exhaust manifold and turbocharger with grease G 000 500 and tighten to 45 Nm.
Tighten oil return pipe to 40 Nm.
Fill the turbocharger with engine oil via the oil supply connection.
Install oil supply pipe with new seal and tighten cap nut to
25 Nm.
Tighten front exhaust pipe to 25 Nm.
After installing the turbocharger, run engine for approx. 1 minute at idling speed, do not rev. up immediately. This ensures the turbocharger is properly lubricated.