Removing and installing turbocharger (engine code CATA) — VW

🧭 Before you start

Fits: VW Touareg I (7L, 2002–2010)

• Renewed: turbocharger, charge air cooler, gaskets

Don't miss

• For greater clarity, shown with intermediate pipe removed.Disregard (item 1) and (item 2).
• Disregard (item 2).
• To prevent damage, do not place removed turbocharger on upper part of oil return line.
• The O-ring must not be damaged. — Tighten turbocharger bolts (arrows).

🔧 Engine codes this applies to

📐 18 workshop diagrams for CATA

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

📋 Procedure

1. ⚠ If a mechanical fault is discovered on the turbocharger (e.g. a destroyed compressor impeller), it is not sufficient to just renew the turbocharger. To avoid any subsequent damage, the following work must be carried out:Check air filter housing, air filter element and air inlet hoses for contamination.Check the whole charge air path and charge air cooler for foreign objects.If foreign objects are discovered in the charge air system, clean the charge air path and, if necessary, renew the charge air cooler. — Remove the engine cover panel. To do this, pull sharply upwards on the front of the cover panel, then on the rear of the cover panel (arrows).
2. Loosen spring-type clip (arrows) and remove air intake hose.
3. Remove bolts (2) and (3).
4. Loosen hose clip (1) and pull air intake pipe forwards off air intake hose.
5. Remove bolts (left arrows) and place air intake with hose connected (right arrow) aside.

6. Disconnect electrical connector (2) at turbocharger 1 control motor V280.
7. Remove bolt (1) and banjo bolt (3) for oil supply line on turbocharger.
8. Remove bolts (1), loosen bolt (2) and remove heat shield for turbocharger.
9. Cover opening (arrow) in gearbox to prevent small parts from dropping in. [Note: For greater clarity, shown with intermediate pipe removed.Disregard (item 1) and (item 2).]
10. Remove nuts (arrows) and pull starter catalytic converter off turbocharger.
11. Disconnect connector (1) (black) for exhaust gas temperature sender 1G235. [Note: Disregard (item 2).]
12. Remove bolts (arrows) for turbocharger.
13. ⚠ Danger of damaging both pipes for oil return line.The upper part of oil return line (3) secured to the turbocharger must be carefully pulled off the lower part of oil return line (5).To avoid bending the two pipes of the oil return line, move the turbocharger (4) slightly backwards and forwards while pulling it off upwards and towards one side. — Remove turbocharger.
14. Seal open lines and unions with clean plugs from engine sealing plug setVAS 6122. [Note: To prevent damage, do not place removed turbocharger on upper part of oil return line.] [Note: Renew gaskets, seals and O-rings.Hose connections and hoses for charge air system must be free of oil and grease before assembly.Secure all hose connections with hose clips (same as original equipment) Parts catalogue.In order to be in a position to securely attach the charge air hoses on their connections, the worm screws of the used hose clips have to the sprayed with penetrating spray before installing.Fit all heat insulation sleeves in the original position when installing.Fill turbocharger with engine oil at oil supply line connection.After installing the turbocharger, run engine for about 1 minute at idling speed and do not rev up immediately to ensure that the turbocharger is fully primed with oil.]
15. Prepare turbocharger for installation. To do this, push on connecting hose (1) and both hose clips (2) onto turbocharger flange.
16. Fit the new O-ring (1) on lower part (5) of oil return line.
17. Lightly lubricate O-ring and inner sealing surface on upper part (3) of oil return line.
18. When fitting turbocharger in place (4), guide upper part (3) of oil return line through intermediate flange (2) to lower part (5) of oil return line.
19. Place upper part of oil return line carefully on lower part of oil return line.
20. ⚠ The O-ring must not be damaged. — Tighten turbocharger bolts (arrows).
21. Install starter catalytic converter.

Other VW procedures

• Removing engine · 41 torque figures
• Removing and installing camshaft · 47 torque figures
• Adjusting valve timing · 83 torque figures
• Removing and installing camshafts · 39 torque figures
• Removing and installing coolant pump · 53 torque figures
• Assembly overview - camshaft housing, engine codes CHPA, CMBA, CPVA, CXSA, CZCA, CPVB, CZDA
• Removing fan housing
• Checking fuel flow rate
• Retrofitting new-version hinges
• Checking the Coolant Temperature Sender