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 right front wheel. Remove catalytic converter. Unscrew heat shield for left drive shaft -arrows-.
Detach vacuum hose -1- from boost pressure control vacuum unit and lay it aside. Remove bolts -2- and remove air pipe from turbocharger. The air inlet remains in the installation position
Detach air hose -3- from turbocharger. Remove nuts -1-. Shown with engine removed for clarity. Bolts -2 and 3- are loosened later.
Unscrew heat shield from turbocharger -arrows-. Remove the hood. If present, unfasten the bracket. Remove engine cover -arrows-. To remove the noise under it against the insulation.
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 wiper blade levers -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 vent grille. Remove rubber seal -1- from deflector grille. Remove air vent grille -2-.
Remove nuts and bolts -arrows-. Pull the fresh air duct forward and remove it by turning it towards the right side of the vehicle.
Detach air hose -3- from intake manifold flap motor -V157-, to do this unclip clamp -2- slightly. Detach vacuum hose -1- from mechanical EGR valve. 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. Pull out air pipe together with air mass meter -G70-.
If fitted, unplug electrical connector -arrow- for crankcase ventilation heater -N79-. Remove air pipe.
Unplug electrical connector -arrow- for intake manifold flap motor -V157-. Remove bolts -1...3- and remove intake manifold flap motor -V157-.
Unclip coolant hoses at exhaust gas recirculation cooler -3094-. Detach the coolant hoses from the exhaust gas recirculation system from the radiator.
Remove bolts -2 and 3- and remove exhaust gas recirculation cooler. Pos. -1- ignore.
Remove bolts -arrows- and remove intake manifold.
Detach oil pre-supply line -2- to turbocharger from oil filter bracket. Unscrew bracket for oil pre-feed line -3-. Pos. -1- ignore.
Loosen bolt -1- by approx. 3 turns. Loosen nut -2-. Unscrew oil return pipe -3- from turbocharger and lay it to one side.
Unbolt bracket for air pipe from sump -arrows-.
Remove bolts -1 and 2- and remove turbocharger support. Unscrew oil return pipe -3- from cylinder block.
Unscrew lower nuts -arrows 2-.
Remove bolts -1- for pendulum support. Pos. -2- and -3- are ignored.
Unscrew top nuts -arrows 1-. Remove the turbocharger by lifting it up to the left.
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 the hose fitting 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 air ducts in the clamps. Install the wiper arm. Check oil level. 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 cylinder head: 25 Nm 1)
- Heat shield to turbocharger: 22 Nm
- Turbocharger support to cylinder head: 25 Nm
- Oil return pipe to cylinder head: 30 Nm
- Oil pre-supply pipe to turbocharger: 22 Nm
- Oil pre-feed pipe to oil filter bracket: 22 Nm
- EGR cooler to mechanical EGR valve: 22 Nm
- EGR cooler to intake manifold: 20 Nm
- EGR cooler to turbocharger: 22 Nm 1)
- Intake manifold flap motor -VI57- to mechanical EGR valve: 10 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.
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