Figure 4.46a. Turbocharger with attached components: 1, 4, 7, 15, 27 - Bolts; 2 - Bushing; 3, 5, 11, 26 - Nuts; 5, 16, 19, 20, 24 - Oil seals; 6 - Exhaust manifold; 8 - Heat-protective casing; 9 - Retainer; 10, 12, 13 - Hairpins; 14 - Lid; 17 - Oil pressure line; 18, 21, 23 - Adapters; 22 - Oil drain line; 25 - Turbocharger.
Figure 4.46b. Intercooler: 1 - Clamps; 2, 4, 10 - Discharge pipes; 3 - Boost air supply pipe; 5 - To the turbocharger; 6 - Intake manifold; 7 - Gasket; 8 - Adapter: 9 - Bolt; 11 - Sealing ring;12 - Radiator.
Removal
1. Disconnect the negative cable from the battery.
2. Loosen the mounting bolts (arrows) and remove the heat shield 1 (figure 4.47).
Figure 4.47. Loosen the mounting bolts (arrows) and remove the heat shield 1.
3. Disconnect the clamps 1 and remove the tubes (arrows) from the oil separator (figure 4.5). Remove the tubes as an assembly.
4. Disconnect the discharge pipe (arrow) from the turbocharger (figure 4.48).
Figure 4.48. Disconnect the discharge pipe (arrow) from the turbocharger.
5. Disconnect the pressure 1 and drain 2 oil lines from the turbocharger (figure 4.49).
6. Remove the front part of the exhaust pipe, unscrew the nuts securing the turbocharger to the exhaust manifold.
7. Remove the turbocharger.
Installation
8. Installation is carried out in the reverse order of removal.
Examination
The turbocharger and the boost pressure control valve form one unit. If the fault occurs with the turbochargers, the entire unit must be replaced. Repairs are not permitted.
Boost pressure is measured at full load either on the road or on a dyno. The test lasts approximately 10 seconds.
Figure 4.49. Disconnect the pressure 1 and drain 2 oil lines from the turbocharger.
9. Disconnect the test tube (black) between the boost pressure limiting valve and the compressor outlet.
10. Attach the additional tube to the compressor and connect the test tube to the T-piece.
11. Connect the VAG 1397 A/1 tube to the VAG 1397 A tester with a T-piece (figure 4.50).
Figure 4.50. Connect the VAG 1397 A/1 tube to the VAG 1397 A tester with a T-piece.
12. Turn on measurement level II.
13. Measure the boost pressure with the throttle fully depressed: on the test bench - in 3rd (for manual transmission) or 2nd (automatic transmission) gear at 3500 rpm, and on the road - in 2nd (for manual transmission) or 1st (automatic transmission) gear at 40 km/h. At 2000-3000 rpm, press the "M" button on the tester and read the measured value. It should be 0.90-1.00 bar.
14. If the value does not match the required value, replace the turbocharger.
15. If the boost pressure is too high and the wastegate valve is not locked, loose or leaking, replace the turbocharger again.
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