Safety regulations
ATTENTION: When performing installation work, especially in the engine compartment due to its dense layout, the following instructions must be observed. All types of lines (for example, fuel, hydraulic, activated carbon absorber, cooling system, air conditioning system circuit, brake system, vacuum), and electrical wires must be laid as they were originally laid. Sufficient space must be provided when working with all moving or heated components.
Removal
Caution: If mechanical defects of the turbocharger are detected, for example, the destruction of the pump section wheel, it is not enough to simply replace the turbocharger. To avoid subsequent damage, after carrying out repair work it is necessary to: Check the air filter housing, filter element and air intake hoses for contamination. Check for foreign bodies in the intake tract and intercooler. If found, remove them from the intake tract, replace the intercooler if necessary.
Remove the air intake pipe "1" and disconnect the connector from the turbocharger guide vane position sensor "G581" "2" on the turbocharger. Disconnect the vacuum line "3" from the turbocharger.
Disconnect the connector of the exhaust gas temperature sensor 1-G235- "1" on the front wall of the water drainage box and remove the cable from the fasteners.
[The original article is posted on the website: VWManual.ru]
Unscrew the oil supply line "arrow" from the turbocharger.
Loosen the fastening screw "1" of the boost air pipe, loosen the clamp "2" and disconnect the connecting hose from the turbocharger, moving the hose as far as possible. Remove the particulate filter.
Remove the connecting pipe "A" to the EGR radiator.
Caution: Exhaust gas temperature sensor 1 -G235- blocks access to the upper mounting bolt of the turbocharger support bracket. The sensor must not be bent, so it must be removed.
Remove the exhaust gas temperature sensor 1 "G235". Disconnect the right drive shaft from the transfer case. Unscrew the hollow screw of the turbocharger support bracket.
Remove the upper "arrow" screw of the turbocharger support bracket.
Rotate the lower part of the support bracket 90° and pull it downwards from the upper part. Remove the exhaust manifold heat shield. Unscrew the exhaust manifold mounting nuts. Remove the turbocharger by turning it with the air intake side down and then lowering it.
Installation
Caution: Before installation, check that the bellows of the return oil line is not bent or twisted. If so, there is a high probability of microcracks, which may lead to leaks. If necessary, replace the return oil line before installing the turbocharger.
Install in the reverse order. Observe the following. Install the turbocharger with the compressed air supply side facing upwards. Install the connecting hose of the charge air pipe before screwing on the turbocharger. Observe the installation position of the exhaust gas temperature sensor 1 "G235". Replace the hollow screw of the turbocharger support bracket and the sealing rings of the oil return line. When installing the turbocharger support bracket, do not twist the bellows of the oil return line.
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