Removal and Replacement
Turbocharger
Special tools, testers and auxiliary items required
- Torque wrench V.A.G. 1331
- Torque wrench V.A.G. 1410
- Old oil collecting and extracting device V.A.G. 1782
- Socket set, 30-piece VAS 5451
- Drip tray for workshop crane VAS 6208
- Hose clamp pliers VAS 6340
- Support channel VW 457/1
- Engine support 3300 A
Note: The Turbocharger can only be installed, removed and replaced as a complete unit with the exhaust manifold and vacuum diaphram.
Changing the Support Channels using the VW 457/1
- A new hole is required in order to attach the support channels VW 457/1 to the subframe.
- Drill a 8.5 mm dia. hole -arrow- into support channel VW 457/1.
- Remove engine cover. Pull cover upward -arrow A- and the pull forward out of rear securing elements -arrow B-.
- Remove the insulation -arrow-.
- Remove noise insulation.
- Drain engine oil into V.A.G. 1782.
- Remove the front exhaust pipe from the turbocharger -arrows-.
Note: Do not bend the flex joint in front of the exhaust pipe more than 10 degrees as it can be damaged.
- Remove the front exhaust pipe bracket from the turbo charger -arrows-.
- Separate the exhaust at the clamp -arrows- and remove the front exhaust pipe and catalytic convertor.
- Remove the heat shield for right drive axle.
- Remove the right drive axle from the output flange and tie it up out of the way as far as possible.
- Unscrew bolts -2- and -3- and remove the turbocharger support.
- Remove oil return line -1- at cylinder block.
- Remove the hose -4- on the boost pressure regulation reservoir from the turbocharger.
- Open the clamp and remove the guide hose -5- from the turbocharger.
- Remove the air guide hose -6-. When doing this, slightly lift the retaining clamps.
- Remove the connecting pipe for exhaust gas recirculation -arrows-.
- Remove heat shield from the exhaust manifold -arrows-.
- Disconnect oil supply line on the turbocharger and on the exhaust manifold -arrows-.
- Remove the oil supply line on the oil filter bracket -arrow- and also on the cylinder head. Push the oil supply line to the left, under the coolant hose.
- Remove the pendulum support bolts -arrows A- and -arrows B-.
- Tighten the channel support VW 457/1 to both threaded holes for the mounting bolts/pendulum supports to the subframe.
- Insert a 6mm spacer between the subframe and the channel support VW 457/1.
- Install the engine support 3300 A and tighten -arrows-.
- Carefully push the engine/transmission subassembly forward.
Note: When moving the engine/transmission assembly, pay attention to all the oil lines and radiator so they do not get damaged.
- Remove the bracket -1- from the exhaust manifold -2-.
- Remove the nuts -arrows-.
- Remove the exhaust manifold/turbocharger -1- between the drive axle -2- and subframe -3-.
Installing
Note: If mechanical damage is found on the turbocharger, e.g. a destroyed compression wheel, it is not enough to just replace the turbocharger. Perform the following steps to prevent subsequent damage.
Clean all oil lines.
Change the engine oil and filter.
Check the air filter housing, the air filter insert and the intake hoses for contamination.
Check entire air charge circuit for debris contamination.
If debris contamination is found in the air circuit. It must be cleaned and the cooler must be replaced if necessary.
- Installing is performed in reverse order. When doing this note the following.
- Seals, sealing rings and self-locking nuts must always be replaced.
- Pay attention to the installation position of the seal for the exhaust manifold/turbocharger.
- Add oil to the turbocharger through oil feed line connecting piece.
- Hose connections and charge air system hoses must be free of oil and grease before installing. Only on connector couplings, the sealing surfaces must be lightly oiled.
- Charge air system must be properly sealed.
- All hose connections for charge air system are secured by spring type clamps or by connector couplings.
- Install the front of the exhaust system together with the catalytic convertor.
- Install the right axle shaft.
- Check engine oil level.
NOTE: After installing turbocharger, let engine idle for approx. 1 minute without increasing engine speed. This ensures adequate oil supply to the turbocharger.
Torque specifications
Component Nm
Exhaust manifold/turbocharger to cylinder head 25 *
Heat shield to exhaust manifold/turbocharger 20 *
Connecting pipe for exhaust gas recirculation 22 *
Oil supply line to turbocharger 22
Bracket for oil supply line to exhaust manifold 22 *
Bracket for turbocharger to cylinder block 40
Bracket for to cylinder block 40
Turbocharger bracket to turbocharger 20
Oil return line to cylinder block 30
Oil supply line to oil filter bracket 25
Pendulum supports to subframe 25
* Replace nuts