Table of contents: Removal ↓ Installation ↓
Removal
Caution! If mechanical damage to the turbocharger is detected (for example, damage to the supercharger impeller) it is not enough to replace the turbocharger alone. To avoid further malfunctions, it is necessary to check the air filter housing, replaceable air filter element and air duct hoses for contamination. 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, loosen bracket "1". Remove the engine cover "arrows". Remove the sound insulation underneath.
Lift the caps "3 and 4" of both parts of the windshield wiper arm with a screwdriver. Loosen the nuts of both parts of the windshield wiper arm with a few turns. Loosen the arms "1 and 2" of the windshield wipers on the axles one by one with light rocking movements. Completely unscrew the nuts and remove both parts of the windshield wiper arm. If it is not possible to remove the arm in this way, then in this case it is necessary to use a standard puller.
Disconnect the washer fluid supply pipe "3". If present, disconnect the plug connectors "4 and 5" of the heated windshield washer nozzles. Loosen the hose clamp "6" using hose clamp pliers "V.A.G 1921" and remove the drain hose from the deflector grille. Remove the rubber seal "1" of the deflector grille. Remove the deflector grille "2".
Unscrew the nuts and bolts of the "arrow". Pull the fresh air supply channel forward and remove it, turning it to the right side of the car.
Disconnect the air duct hose "2" from the mechanical EGR valve. Disconnect the vacuum hose "3" of the mechanical EGR valve. Disconnect the vacuum hose "4" of the intake manifold flap power vacuum pneumatic element. Ignore item "1".
Remove the air duct hose "2" from the intercooler.
Disconnect the air duct hose "1" from the air flow meter "G70". Disconnect the plug connector "3" of the air flow meter "G70". Unscrew the nut "2". Remove the crankcase ventilation hose "4" from the cylinder head cover. Unfasten the fuel lines on the air guide pipe. The air guide pipe remains in the car. Remove the right front wheel. Remove the catalytic converter.
Unscrew the heat shield of the left drive shaft "arrow".
Unscrew the air guide pipe bracket from the oil pan "arrows".
Disconnect the air duct hose "6" from the turbocharger. Remove the oil return pipe - to do this, unscrew the nuts "2" and nut "1". Disconnect the hoses "5" of the boost pressure control system to the turbocharger and the boost pressure control pneumatic power element. Disconnect the ventilation hose "4". Unscrew the bolts "3" and remove the air guide pipe from the turbocharger. The air guide pipe remains in the car.
Loosen bolt "1" by about 3 turns. Unscrew oil return pipe "3" from turbocharger and put it aside. Ignore item "2".
Unscrew the lower nut "arrow" of the turbocharger. Pull up the air duct hose loosened from below to the turbocharger.
Unscrew the heat shield of the exhaust manifold "arrows".
Remove the connecting pipe of the exhaust gas recirculation system "pos. 1 and 2".
Loosen the "arrow" bolts and remove the intake manifold. Loosen both "arrow" bolts of the turbocharger, while holding the turbocharger. Place the turbocharger on the subframe. Remove the turbocharger downwards.
Installation
Installation is in the reverse order, replacing the seals, cuffs and self-locking nuts. Fill the turbocharger with engine oil up to the connecting nipple of the oil pre-supply line. The supercharging system must be sealed. The hoses and hose nipples of the air supercharging system must be cleaned of oil and grease before installation. Use clamps of the appropriate series to secure all hose connections.
Install the intake manifold. Install the EGR connecting pipe by first tightening it and then tightening the bolts all the way. Install the catalytic converter. Install the air ducts in the clamps. Install the wiper arm. Check the oil level.
Instructions: After completing the turbocharger installation, run the engine in idle mode for about 1 minute, without developing high speeds, 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
- Turbocharger oil return line: 30 Nm
- To the cylinder block: 15 Nm
- Turbocharger pre-supply oil line: 22 Nm
- Air guide pipe to turbocharger: 8 Nm
- Air guide pipe to oil pan: 8 Nm
- Air guide pipe to body: 8 Nm
- Heat shield drive shaft to cylinder block: 33 Nm
- engine compartment cover to bracket: 5.5 Nm
1) Replace the nuts.
(The original version is on the portal: Audimanual.ru)