Withdrawal
Remove the engine hood. Remove engine cover. Remove the noise shield located below, to do this, disconnect the crankcase breather hose. Use a screwdriver to remove caps -3- and -4- from wiper arms. Loosen the nuts on both levers a few turns. Release levers -1- and -2- by slightly deflecting them on the wiper shafts. Loosen nuts completely and remove wiper arms.
Disconnect the washer fluid pipe -3-. Unplug electrical connectors -4- and -5- for heated washer nozzles. Unclip hose clamp -6- Using hose clamp pliers -VAG 1921-, remove drain hose from fairing grille. Remove rubber seal -1- for fairing grille. Remove fairing grille -2-.
Remove bolts and nuts -arrows-. Remove the fresh air intake duct and hang it over the right side of the vehicle.
Unplug electrical connector -2- from air mass meter -G70-. Detach vacuum hose -1-. Release hose clamp -4- and remove air duct with air mass meter -G70-. Loosen nut -3-.
Remove the air hose -2- connecting the intercooler and intake manifold Pos. -1- ignore.
Detach vacuum hose -1- from mechanical 0G recirculation valve. Detach vacuum hose -2- from throttle valve control valve -N211-.
Attention! The temperature of the fuel lines or the fuel in vehicles equipped with a unit injector engine can reach 100°C. Allow the fuel to cool before disconnecting the fuel lines, otherwise severe burns may result.
Mark and disconnect fuel pressure line -2- and fuel return line -1-.
Remove bolts -arrows- and remove air duct from turbocharger.
Remove bolts -2- on pre-catalyst bracket. Pos. -1- ignore.
Unscrew nuts -arrows- for precatalyst/turbocharger.
Instruction. The split piece between pre- and main catalytic converter must not be bent more than 10°. Risk of damage!
Disconnect the pre-catalyst from the turbocharger. Tie the pre-catalyst to the body.
Clamp off coolant hoses leading to exhaust gas recirculation cooler with hose clamps -3094-. Detach coolant hoses -arrows- from exhaust gas recirculation cooler.
Remove bolts -2- and -3- and nuts -1- and remove exhaust gas recirculation cooler.
Unscrew bolts -arrows- and remove intake manifold.
Detach air hose -1- from turbocharger. Unscrew oil pressure line -2- from turbocharger. Remove 3 nuts -3- for turbocharger.
Detach vacuum hose -2- from vacuum charge pressure regulator and free it. Detach oil return line -3- from cylinder block. Unbolt support -1- for turbocharger from cylinder block. Pull turbocharger upwards.
Installation
Install in the reverse order, while replacing gaskets, collars and self-locking nuts. Fill the turbocharger with oil through the connecting pipe of the pressure oil line. The boost system must be sealed. The hoses and fittings of the air pressurization system must be cleaned before installing oils and greases. Use clamps of the appropriate series to fasten all hose connections. Install intake manifold. Install the preliminary main catalytic converter. Install and adjust wiper arms. Check oil level.
Instruction. After installing the turbocharger, leave the engine to idle (do not increase the speed for 1 minute to make sure that oil is supplied to the turbocharger.
Tightening torques:
- Turbocharger to exhaust manifold: 25 Nm 1)
- Turbocharger support to cylinder block: 20 Nm
- Return oil line of cylinder block: 30 Nm
- Pressure oil line to turbocharger: 22 Nm
- Intake manifold to cylinder head: 25 Nm
- EGR cooler to EGR mechanical valve: 25 Nm
- EGR cooler to intake manifold: 25
- EGR cooler to exhaust manifold: 25
- Air duct to turbocharger: 8 Nm
1) Replace nuts.
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