Removing and installing turbocharger, single turbo — VW

Removing and installing turbocharger, single turbo
Special tools and workshop equipment required
Torque wrench
V.A.G 1331
Torque wrench
V.A.G 1332
Engine bung set
VAS 6122
High-temperature paste
Electronic Parts Catalogue
Removing
Observe rules for cleanliness when working on charge air system
Chapter
.
Note
Immediately seal open connections with suitable plugs from
engine bung set
VAS 6122
.
Only use clean plugs.
If fitted, remove underbody guard
General body repairs, exterior
Rep. gr.
66
Underbody guard; Removing and installing underbody guard
.
Remove air filter housing
Chapter
.
Vehicles with particulate filter
Remove particulate filter
Chapter
.
Vehicles with catalytic converter
Remove front exhaust pipe with catalytic converter
Chapter
.
Continuation for all vehicles
Loosen clip
2
.
Pull charge air hose
1
off turbocharger.
Note
Two different versions of exhaust gas recirculation cooler may be installed.
Version with vacuum unit for exhaust flap on exhaust gas recirculation cooler
Disconnect connectors
1
at
position sender for charge pressure positioner
G581
3
.
If fitted, disconnect connector
4
at
charge pressure sender 2
G447
1
.
Remove pipe
Item
.
Remove bolts
2 and 3
.
Remove pipe
1
from exhaust gas recirculation cooler.
Version without vacuum unit for exhaust flap on exhaust gas recirculation cooler
Unscrew bolts
1, 2 and 3
.
Remove bracket
5
.
Detach exhaust gas recirculation cooler
4
.
Continuation for all
Unscrew bolts
2 and 3
for support
1
.
Remove bolt
1
.
Remove support
4
.
Unscrew bolts
2
of oil pressure line
3
.
Unscrew nuts
1 to 8
.
Remove turbocharger with exhaust manifold upwards.
Unscrew bolts
1
on coolant pipe bracket
2
.
Remove gasket for exhaust manifold
3
.
Installing
Installation is carried out in the reverse order; note the following:
Note
Renew connecting pipes after each removal.
Renew seals, gaskets and self-locking nuts.
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.
Observe tightening sequence for turbocharger
Item
.
Fit oil pressure line bolts
Item
with
high-temperature paste
Electronic Parts Catalogue
.
Vehicles with particulate filter
Install particulate filter
Chapter
.
Vehicles with catalytic converter
Install front exhaust pipe with catalytic converter
Chapter
.
Install air filter housing
Chapter
.
If removed beforehand, reinstall underbody guard
General body repairs, exterior
Rep. gr.
66
Underbody guard; Removing and installing underbody guard
.
Specified torques
Chapter
“
Assembly overview - turbocharger, single turbo
”
Chapter
“
Assembly overview - emission control, diesel particulate filter
”
Chapter
“
Assembly overview - emission control, catalytic converter
”
Chapter
“
Assembly overview - air filter housing
”