Removing and installing turbocharger, water-cooled turbocharger — VW

🧭 Before you start

Fits: VW Passat B8 (3G, 2014–)

• Opens: coolant
• Renewed: turbocharger, charge air cooler, seals

Don't miss

• When removing the emission control module, bear the wire of the exhaust gas temperature sender 1G235(1) in mind.
• When installing coolant pipe (1), make sure that guide (2) is properly seated in bracket.

🔧 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. — Observe rules for cleanliness .
2. Remove engine cover panel .
3. Remove battery tray (1)Electrical system27Battery; Removing and installing battery tray.
4. Drain coolant .
5. Remove air filter .

6. Remove front exhaust pipe .
7. Remove coolant pipe (rear) .
8. Remove coolant pipes (left-side) .
9. On vehicles with auxiliary heater, remove coolant lines from plenum chamber bulkhead Auxiliary heater82Coolant circuit with auxiliary/supplementary heaters; Removing and installing coolant pipes for auxiliary/supplementary heaters.
10. Open heat insulation sleeve (1).
11. Open heat insulation sleeve on vacuum unit.
12. Release connectors (3) to (6), pull them off, and lay wiring harness to one side.
13. Remove bolt (2).
14. Move bracket with pressure differential senders towards rear.
15. Move wiring harness on bracket clear to one side.
16. Remove bolt (2).
17. Move bracket with pressure differential senders towards rear.
18. Remove connector (1) from retainer.
19. Release and pull off connector.
20. Lay wiring harness to one side.
21. Release and detach connector (2) from charge pressure control solenoid valve N75(1).
22. Remove nuts (arrows).
23. Place charge pressure control solenoid valve N75(1) with vacuum lines on engine.
24. Remove connection from turbocharger .
25. Unscrew bolts (arrows) on turbocharger.
26. Remove resonator (1).
27. Remove coolant pipe (1) on turbocharger and on engine.
28. To do this, unscrew bolts (arrows).
29. Release connector (3), pull it off, and unclip wiring harness.
30. Guide out coolant pipe (1), and push it aside.
31. Release and pull off electrical connectors (3) to (5).
32. If fitted, release and pull off connector (2).
33. Lay wires to one side.
34. Unscrew bolts (arrows) and remove heat shield (1).
35. Pull vacuum hose (2) from turbocharger vacuum unit.
36. Open clamp (arrow), and pull coolant hose (1) off coolant pipe (2).
37. Loosen and open clamp (1).
38. Remove injector for reducing agent N474.
39. Remove injector for reducing agent N474, and lay it to one side with lines connected.
40. Remove bolt (3).
41. Unclip pipe (2) on toothed belt guard.
42. Remove exhaust gas recirculation cooler .
43. Push heat insulation sleeve to one side and unplug electrical connector (5).
44. Release hose clip (3) and detach air hose.
45. Release hose clip (4) and detach coolant hose.
46. Unscrew bolt (1) using bit XZN 10T10501 and loosen bolt (2).
47. Loosen bolt (1) and remove screw-type clip.
48. Unscrew bolts (arrows) and push emission control module and exhaust gas recirculation cooler towards rear. [Note: When removing the emission control module, bear the wire of the exhaust gas temperature sender 1G235(1) in mind.]
49. Unscrew bolt (2) and union nut (4).
50. Unscrew bolts (3 and 5) and detach oil return line.
51. Unscrew bolts (1 ... 4) and remove bracket for diesel particulate filter.
52. Unscrew nuts (arrows), pull turbocharger with exhaust manifold off cylinder head and remove it upwards. [Note: Renew seals, gaskets, O-rings and self-locking nuts after removal.Fill turbocharger with engine oil at connection for oil supply line.Hose unions and air intake pipes and hoses must be free of oil and grease before installation.Secure all hose connections with hose clips meeting production standard Electronic Parts Catalogue.After installing turbocharger, run engine for about 1 minute at idling speed to ensure that oil is supplied to turbocharger.]
53. When installing coolant pipe (1), make sure that guide (2) is properly seated in bracket.
54. Electrical connections and routing Electrical system97Relay carriers, fuse carriers, electronics boxes; Overview of fitting locations - relay carriers, fuse carriers, electronics boxes and .
55. Install left coolant pipes .
56. Install rear coolant pipe .
57. Install emission control module .
58. Install front exhaust pipe .
59. Connect vacuum hose .
60. Fit engine cover panel . [Note: After new components have been installed (engine/short engine, cylinder head, camshaft housing or turbocharger) the oil pressure control must be set to max. pressure for approx. 1000 km. This will compensate for the increased friction during run-in of new components, and a better transport of particles produced during run-in is guaranteed. To do this, connect vehicle diagnostic tester, switch on ignition, and select the following menu options:Self-diagnosis-capable systems0001 - Engine electronics 0001 - Engine electronics, functions0001 - AdaptationOil pressure control/activate run-in function]

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