VW Passat & Audi A4 1990-2000

Turbocharger

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REMOVAL & INSTALLATION
1.8L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine undercover.
  4.  
  5. Remove the air conditioning compressor mounting fasteners. Remove the compressor leaving the lines attached. Support the compressor such that the lines are not stretched or kinked.
  6.  
  7. Unbolt the turbocharger support bracket.
  8.  
  9. Disconnect the oil return line at the turbocharger.
  10.  
  11. Remove the air hoses from the turbocharger.
  12.  
  13. Disconnect the oil feed line at the turbocharger.
  14.  
  15. Disconnect the hose for the boost pressure regulation valve vacuum diaphragm.
  16.  
  17. Unbolt the bracket for the coolant supply line at the boost pressure regulation valve vacuum diaphragm.
  18.  
  19. Using clamp Tool No. 3094, or equivalent, pinch off the coolant supply hose.
  20.  
  21. Remove the intake air duct between the cowl and the air cleaner housing.
  22.  
  23. Remove the air cleaner housing cover.
  24.  
  25. Label and detach the following lines and electrical connectors:
  26.  
  27. Wastegate bypass regulator valve
  28.  
  29. Evaporative Emission (EVAP) canister purge regulator valve
  30.  
  31. Power outage stage
  32.  
  33. Mass Air Flow (MAF) sensor
  34.  
  35. Remove the air cleaner housing and the engine cover.
  36.  
  37. Disconnect the crankcase breather hose at the valve cover.
  38.  
  39. Disconnect the oil supply line at the turbocharger.
  40.  
  41. Remove the heat shield, and sleeve from the coolant return hose.
  42.  
  43. Using clamp Tool No. 3094, or equivalent, pinch off the coolant return hose, then remove.
  44.  


WARNING
The exhaust flexpipe may be damaged if bent more than 10°.

  1. Disconnect the Three Way Catalytic Converter (TWC) from the turbo.
  2.  
  3. Unbolt the turbo from the exhaust manifold.
  4.  
  5. Move the turbo aside to disconnect the coolant supply banjo fitting.
  6.  
  7. Remove the turbo.
  8.  



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Fig. exploded view of the turbocharger and related components-1.8L Engine



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Fig. Exploded view of the vacuum hoses related to the turbocharger-1.8L Engine



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Fig. The turbo-charger as viewed from the engine compartment

To install:

  1. Install the turbo, coating the fasteners with Hot Bolt Paste, G 052 112 A3 or equivalent.
  2.  
  3. Connect the coolant supply banjo fitting and tighten to 18 ft. lbs. (25 Nm).
  4.  
  5. Using new gaskets, install the turbocharger to the exhaust manifold, coat the bolts with Hot Bolt Paste, then tighten the mounting bolts to 26 ft. lbs. (35 Nm). Tighten the turbo support bracket mounting bolts to 33 ft. lbs. (45 Nm).
  6.  
  7. Attach the TWC converter to the turbo.
  8.  
  9. Connect the coolant supply hose.
  10.  
  11. Install the sleeve and heat shield to the return hose.
  12.  
  13. Connect the oil return hose.
  14.  
  15. Make sure the openings are clear and clean. Add fresh engine oil to the turbo through the oil feed line.
  16.  
  17. Connect the oil supply line to the turbo and tighten to 18 ft. lbs. (25 Nm).
  18.  
  19. Connect the crankcase breather, then install the engine cover and air cleaner housing.
  20.  
  21. Attach the following lines and electrical connectors:
  22.  
  23. Mass Air Flow (MAF) sensor
  24.  
  25. Power outage stage
  26.  
  27. Wastegate bypass regulator valve
  28.  
  29. Connect the hoses and brackets for the boost pressure regulation valve vacuum diaphragm.
  30.  
  31. Connect the air hoses to the air cleaner assembly and the turbo.
  32.  
  33. Install the air conditioning compressor and engine undercovers.
  34.  
  35. Refill the coolant system and bleed as necessary. For additional information, please refer to the following topic(s): General Information and Maintenance, Fluids and Lubricants.
  36.  
  37. Check the oil level and top off as necessary.
  38.  
  39. Connect the negative battery cable.
  40.  
  41. Enter the radio security code.
  42.  
  43. Start the vehicle and check for leaks, then let the engine idle for approximately 1 minute without increasing the engine speed. This ensures adequate oil supply to the turbo.
  44.  

 
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