Removing and installing turbocharger, engine code BMT: VW Polo 9N 1.9 TDI (ASZ, ATD, AXR, BLT, …)

🧭 Before you start

Fits: VW Polo 9N (2001–2009)

• Renewed: turbocharger, seals

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• Secure steering box to body of vehicle so that hydraulic lines are not stressed.
• Ensure that the heat shield of the particulate filter is properly seated in the retaining clamps on the turbocharger.
• Specified torques for pendulum support

🔧 Engine codes this applies to

📐 53 workshop diagrams for ASZ

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 prevent this from causing further damage, perform the following repairs:Check air filter housing, air filter element and intake hoses for soiling.Check complete charged air routing 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 engine cover panel 15.1.
2. Remove intake air hose from air filter .
3. Loosen connecting pipe for charge air cooler and pull connecting hose off turbocharger and intake manifold.
4. Remove noise insulation tray General body repairs, exterior50.
5. Remove securing bolts (1) and remove cover (2) from cylinder block for right drive shaft.

6. Disconnect right drive shaft at gearbox Running gear, axles, steering40.
7. Unscrew steering from subframe.
8. Remove subframe, the hydraulic steering circuit need not be opened for this Running gear, axles, steering40. [Note: Secure steering box to body of vehicle so that hydraulic lines are not stressed.]
9. Remove front exhaust pipe with particulate filter .
10. Remove turbocharger support .
11. Pull vacuum hose off turbocharger.
12. Unscrew oil supply pipe at turbocharger.
13. Remove connecting pipe to exhaust gas recirculation cooler.
14. Remove securing nuts from intake manifold.
15. Tilt the engine forwards in lower mounting and remove turbocharger with exhaust manifold downwards.
16. Ensure that the heat shield of the particulate filter is properly seated in the retaining clamps on the turbocharger.
17. Renew seals and as well as O-rings . [Note: Specified torques for pendulum support]

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