Removing and installing turbocharger, bi-turbo — VW

Removing and installing turbocharger, bi-turbo
Special tools and workshop equipment required
Torque wrench (5…50 Nm)
V.A.G 1331
Torque wrench (40…200 Nm)
V.A.G 1332
Torque wrench
V.A.G 1410
Engine bung set
VAS 6122
Engine support
T50015
Caution
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.
Removing
Note
After lines and hoses have been removed, the open connections are to be sealed immediately with a plug from the
engine bung set
VAS 6122
.
Only use clean plugs.
Detach connector
arrow B
from
charge pressure sender 2
G447
1
.
Unscrew bolt
arrow A
, remove
charge pressure sender 2
G447
1
with bracket from air filter and lay aside.
Remove air filter housing
Chapter
.
Unclip vacuum lines
B
from retainer.
Pull crankcase breather hose
1
off.
Loosen clip
A
and remove intake hose.
Detach connector
arrow A
from
regulating flap potentiometer
G584
1
.
Detach hose
arrow B
from
regulating flap potentiometer
G584
1
and place to one side.
Detach vacuum hose
arrow
from vacuum pump
1
and place to one side.
Loosen bolt
arrow
of clamp
1
and push clamp onto particulate filter.
Disconnect connector
arrow B
from
exhaust temperature sender 1
G235
and lay wiring harness to one side.
Screw bolts
1
out of connecting pipe
5
.
Unscrew bolts
3
.
Undo and remove bolts
arrows
from bracket
1
and remove bracket.
Place exhaust gas recirculation cooler
2
on the engine.
Note
Coolant hoses can remain connected.
Loosen clip
2
for connecting hose
1
and detach connecting hose from pulsation damper.
Note
Seal opening in turbocharger with clean cloths or similar.
Locate
engine support
T50015
as shown and brace engine.
Undo and remove bolt
arrow
from engine mount on right
1
.
Undo and remove bolt
arrow
from engine mount on right
1
and remove engine mount.
Loosen banjo bolt
arrow
.
Note
Renew the oil return line if it is separated at the clip
Item
or is damaged.
The turbocharger is delivered with a new oil return line. When renewing the turbocharger, always use the new oil return line for the turbocharger.
Undo and remove bolt
2
for turbocharger
1
at lower bracket.
Undo and remove banjo bolt
arrow
from top oil supply line.
Undo and remove banjo bolt
arrow
from bottom oil supply line.
Unbolt bracket
2
for oil supply line
1
from turbocharger.
Undo and remove bolts
1
to
8
for exhaust manifold with turbocharger.
Carefully remove turbocharger with exhaust manifold upwards.
Installing
Installation is carried out in the reverse order; note the following:
Note
Renew connecting pipes after each removal.
Renew all gaskets, O-rings and self-locking nuts.
The turbocharger is delivered with a new oil return line. When renewing the turbocharger, always use the new oil return line for the turbocharger.
Fit new double seal
2
onto the respective line connection
1
and secure by screwing in the corresponding banjo bolt
3
.
Check oil supply line
arrow
for damage after installing
Item
.
Specified torques
Chapter
“
Assembly overview - turbocharger, bi-turbo
”
Chapter
“
Assembly overview - air filter housing
”
Chapter
“
Assembly overview - exhaust gas recirculation
”
Chapter
“
Assembly overview - emission control
”
Chapter
“
Assembly overview - assembly mountings
”