Removing and installing turbocharger on right: VW Touareg II (CKDA)

🧭 Before you start

Fits: VW Touareg II (7P, 2010–2018)

• Renewed: turbocharger, charge air cooler, seals

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• Danger of damage to turbocharger.Do not hold turbocharger by cast iron arm or by control unit for turbocharger 1J724. — Remove turbocharger.
• Danger of damage to turbocharger.Do not hold or adjust turbocharger by cast iron arm or by control unit for turbocharger 1J724. — Install exhaust temperature sender 1G235.

🔧 Engine codes this applies to

📋 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 right catalytic converter .
2. Disconnect electrical connector (5) and remove bolt (1).
3. Release hose clips (2) and (4) and take out air pipes (right-side).
4. Remove bolt (1).
5. Release hose clip (arrow) and detach air pipe on right from turbocharger.

6. Unscrew bolt (3) for bracket for coolant lines.
7. Unscrew bolts (2) for bracket for turbocharger.
8. Unscrew exhaust temperature sender 1G235(item 1).
9. Unscrew bolts (arrows) securing turbocharger to exhaust manifold.
10. Detach electrical connector (5) from turbocharger 1 control unit J724.
11. Disconnect connector (6) on sender 1 for turbocharger speed G688.
12. Remove bolts (2) on oil return pipe.
13. Unscrew union nut (3) for coolant line and banjo bolt (4) for oil supply line.
14. Swivel turbocharger a little to the left and, on the rear, unscrew union nut (1) for coolant line.
15. ⚠ Danger of damage to turbocharger.Do not hold turbocharger by cast iron arm or by control unit for turbocharger 1J724. — Remove turbocharger.
16. Seal holes in turbocharger and charge air path with engine bung setVAS 6122. [Note: Renew seals and gaskets.Do not remove bungs or protective caps until immediately before corresponding lines are fitted.Fill turbocharger with engine oil at oil supply line connection.Hose connections and hoses for charge air system must be free of oil and grease before assembly.Secure all hose connections with the hose clips corresponding to original equipment Electronic Parts Catalogue.After installing turbocharger, run engine for about 1 minute at idling speed to ensure that oil is supplied to turbocharger.]
17. ⚠ Danger of damage to turbocharger.Do not hold or adjust turbocharger by cast iron arm or by control unit for turbocharger 1J724. — Install exhaust temperature sender 1G235.
18. Install air pipes .
19. Install right catalytic converter .

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