Withdrawal
Carefully! In case of mechanical damage to the turbocharger (e.g. damage to the blower impeller) it is not enough to replace only the turbocharger. Check the air filter housing, air filter element and air hoses for dirt to avoid further problems. Check the boost pressure line and intercoolers for foreign bodies. If foreign bodies are found in the boost pressure system, clean the boost pressure line and, if necessary, replace the intercooler.
Remove the hood. If present, unfasten bracket -1-. Remove engine cover -arrows-. Remove the sound insulation underneath.
Pry off caps -3 and 4- on both parts of wiper arm with a screwdriver. Loosen the nuts on both parts of the wiper arm with a few turns. Loosen windshield wiper arms -1 and 2- on axles one by one with light wiggles. Completely unscrew the nuts and remove both parts of the wiper arm. If it is not possible to remove the lever in this way, then in this case it is necessary to use a standard puller.
Disconnect washer fluid pipe -3-. If fitted, unplug electrical connectors -4 and 5- for heated washer jets. Loosen hose clamp -6- using hose clamp pliers -VAG 1921- and remove drain hose from deflector grille. Remove rubber seal -1- from deflector grille. Remove air vent grille -2-.
Remove nuts and bolts -arrows-. Pull forward the channel, supply fresh air and remove it. turning to the right side of the car.
Detach air hose -2- from mechanical exhaust gas recirculation valve. Detach vacuum hose -3- from mechanical exhaust gas recirculation valve. Detach vacuum hose -4- for air intake manifold flap vacuum unit. Pos. -1- ignore.
Remove air duct hose -2- from intercooler.
Detach air hose -1- from air mass meter -G70-. Unplug electrical connector -3- for air mass meter -G70-. Loosen nut -2-. Detach hose -4- for crankcase breather from cylinder head cover. Unfasten the fuel lines on the air pipe. The air guide pipe remains in the vehicle. Remove the right front wheel. Remove catalytic converter.
Unscrew heat shield for left drive shaft -arrows-.
Unbolt bracket for air pipe from sump -arrows-.
Detach air hose -6- from turbocharger. Remove the oil return pipe - to do this, unscrew the nuts -2 - and the nut -1-. Detach hoses -5- from charge pressure control system to turbocharger and charge pressure control air supply unit. Disconnect ventilation hose -4-. Remove bolts -3- and remove air pipe from turbocharger. The air guide pipe remains in the vehicle.
Loosen bolt -1- by approx. 3 turns. Unscrew the oil return pipe -3- from the turbocharger and put it aside. Pos. -2- ignore.
Remove lower nut -arrow- for turbocharger. Pull upwards the air hose loosened from below to the turbocharger.
Remove exhaust manifold heat shield -arrows-.
Remove connecting pipe for exhaust gas recirculation -pos. 1 and 2-.
Remove bolts -arrows- and remove intake manifold. Unscrew both bolts -arrows- for turbocharger while holding turbocharger. Place turbocharger on subframe. Remove turbocharger downwards.
Installation
Reinstall in reverse order, replacing seals, collars and self-locking nuts. Fill the turbocharger with engine oil up to the connecting fitting of the oil pre-supply line. The boost system must be sealed. The hoses and hose fittings of the charge air system must be free of oil and grease before installation. Use clamps of the appropriate series to fasten all hose connections.
Install intake manifold. Install the connecting pipe for the exhaust gas recirculation system, to do this, first screw it in first and then screw in the bolts to the end. Install catalytic converter. Install the air ducts in the clamps. Install the wiper arm. Check oil level.
Instruction. After completing the installation of the turbocharger, run the engine at idle for about 1 minute, without developing a high speed, to ensure the supply of oil to the turbocharger.
Tightening torques:
- Turbocharger to exhaust manifold: 25 Nm 1)
- Heat shield to exhaust manifold: 22 Nm
- Oil return line to turbocharger: 30 Nm
- To cylinder block: 15 Nm
- Oil pre-supply line to turbocharger: 22 Nm
- Air pipe to turbocharger: 8 Nm
- Air pipe to oil pan: 8 Nm
- Air pipe to body: 8 Nm
- Heat shield for drive shaft to cylinder block: 33 Nm
- engine compartment cover to bracket: 5.5 Nm
1) Replace nuts.
Visitor comments