Removing and installing turbocharger, “biturbo engine” — VW

Removing and installing turbocharger,
“biturbo engine”
Special tools and workshop equipment required
Torque wrench
V.A.G 1331
Torque wrench
V.A.G 1332
Torque wrench
V.A.G 1410
Engine bung set
VAS 6122
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.
In order to remove the
“biturbo”
, it must be
»partially dismantled«
. The upper part of the intake pipes with the pulsation damper must be removed upwards. The
“biturbo”
is removed downwards.
Before the
“biturbo”
can be removed, the following parts must be removed:
Complete drive shaft on the right
Rear torque reaction support
Support mounting
Particulate filter
Wiring bracket on subframe
Removing
Observe rules for cleanliness
Chapter
.
Assembly overview - charge-air hose connections
Chapter
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.
Vehicles with four-wheel drive
Rep. gr.
34
Bevel box; Removing bevel box
Continuation for all vehicles
Remove connecting pipe
Chapter
Release and detach connector
arrow
of
exhaust temperature sender 1
G235
. Then, lay wiring harness to one side.
Unscrew bolt
2
and remove from clamp
1
.
Loosen particulate filter
3
.
Note
The nuts may vary depending on the type of engine.
Unscrew nuts
arrows
above and to right of turbocharger.
Unscrew nuts
arrows
above and to left of turbocharger.
Pull lines
2
,
3
and
4
out of mounting for intake hose
1
.
Open screw-type clip
5
wide enough to enable removal of intake hose
1
.
Remove particulate filter
Chapter
.
Remove complete right-hand drive shaft
Running gear, axles, steering
Rep. gr.
40
.
Unscrew bolt
1
from support mounting
3
.
Unscrew bolts
2
and bolt
3
and remove rear torque reaction support
1
.
Note
Note different bolt lengths.
Unscrew bolt
2
of oil supply line
3
.
Caution
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
Item
.
Unscrew bolt
4
and use a cloth to soak up any escaping oil.
Remove all lines from bracket
arrow
. Then remove bracket from subframe.
Pull hose
1
off vacuum unit
2
.
Release connector
1
and pull off from
regulating flap potentiometer
G584
.
Pull hose
2
off
regulating flap potentiometer
G584
3
.
Unscrew nuts
arrows
below and to right of turbocharger.
Unscrew nuts
arrows
below and to left of turbocharger.
Unscrew union nut
4
of oil return line
3
. When doing this, counterhold on connection
5
.
Remove bolt
1
from bracket
2
.
Caution
Avoid damage to oil supply line
Item
. 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.
Cover anti-roll bar with a cloth or similar to avoid damage to paintwork.
Remove turbocharger, tilt to rear and remove via subframe and anti-roll bar.
Once turbocharger has been removed, bolt
2
must be released from bracket
1
for reinstalling.
Note information on oil return line
Item
.
Installing
Installation is carried out in the reverse order; note the following:
Renew seals, gaskets and self-locking nuts.
When turbocharger and connecting pipes are being assembled, it is essential that the correct repair set
Electronic Parts Catalogue
is used.
Fit new double seal
2
onto the respective line connection
1
and secure by screwing in the corresponding banjo bolt
3
.
Bolt
2
must be released from bracket
1
for reinstalling.
Only screw bolt
1
loosely into bracket
2
.
Install connecting pipes
Chapter
.
Caution
Note tightening sequence and procedure when bolting turbocharger on
Fig.
.
Oil supply line
3
must be checked for damage after installing.
Notes on checking
Item
.
Specified torques
Chapter
“
Assembly overview - turbocharger,
biturbo engine
”
Chapter
“
Assembly overview - exhaust gas recirculation cooler,
biturbo engine
”
Chapter
“
Assembly overview - particulate filter
”
Chapter
“
Removing and installing engine mountings
”
Drive shafts; Assembly overview - drive shafts
Running gear, axles, steering
Rep. gr.
40
Drive shaft; Assembly overview - drive shaft
Noise insulation; Assembly overview - noise insulation
General body repairs, exterior
Rep. gr.
66
Noise insulation; Assembly overview - noise insulation