Volkswagen Cars 2000-05

Turbocharger

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Removal & Installation



Turbochargers are subject to enormous amounts of heat and friction due to the speeds at which they operate. On some models the turbine shaft can rotate at speeds up to 70,000 rpm. Most turbo's are cooled and lubricated by a oil supply line from the vehicles engine that feeds the unit a fresh stream of filtered oil. There is also a return line back to the oil pan. The oil in this feed line is the life line of the turbocharger. Its like blood is to a human being, without it, the turbo will cease to operate. This is just another example of why it is important that you change the oil at the manufacturers recommended intervals. If sludge formed in these lines and reduced the flow, the turbocharger unit would wear out very rapidly.


NOTE
If the turbo charger is being replaced, the oil lines going to and from it must be removed and cleaned. If cleaning the lines is not enough, then they must be replaced. Also if the turbocharger is being replaced due to excessive exhaust smoke, there may still be some oil in the exhaust system once the new turbo has been installed. You may have to drive the vehicle for a few miles before this smoke clears.

  1. Disconnect the negative battery cable. If equipped with an automatic transaxle, remove the starter.
  2.  
  3. Remove the nuts to disconnect the exhaust outlet pipe from the turbocharger outlet. If it's necessary to separate the exhaust pipe from the outlet pipe, follow the procedure is described in exhaust manifold removal for gasoline engines before removing the outlet pipe.
  4.  
  5. Clean the oil supply fitting on the top of the turbocharger and remove the supply line and bracket.
  6.  
  7. Remove the inlet air duct.
  8.  
  9. Under the vehicle, remove the oil return line and the turbocharger mounting bracket.
  10.  
  11. Still underneath, remove the turbo-to-manifold bolts and lift the turbocharger out from the top. The exhaust manifold can be removed after removing the EGR valve.
  12.  

To install:

  1. If removed, install the exhaust manifold with a new gasket and torque the bolts to 18 ft. lbs. (25 Nm).
  2.  
  3. Use a new gasket and fit the turbocharger to the manifold. Coat the bolt threads with anti-seize and torque the turbocharger bolts to 33 ft. lbs. (45 Nm) and the bracket nuts to 18 ft. lbs. (25 Nm).
  4.  
  5. Use a new gasket and connect the oil return line. Torque the bolts to 22 ft. lbs. (30 Nm).
  6.  
  7. Use a new gasket and connect the outlet pipe. Torque the nuts to 18 ft. lbs. (25 Nm).
  8.  
  9. Connect the oil supply line, install the EGR valve.
  10.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect:

    Negative battery cable.
     
    Exhaust pipe from the turbocharger outlet.
     
    Oil supply line and bracket, after cleaning the oil supply fitting on the top of the turbocharger.
     
    Inlet air hose.
     
    Oil return line and the turbocharger mounting bracket.
     
    Turbo-to-manifold bolts. Lift the turbocharger out from the top.
     

  4.  

To install:

  1. Installation is the reverse of removal. Before installing the oil supply line, fill the connection on the turbocharger with engine oil.
  2.  
  3. Tighten the following:

    Turbocharger-to-exhaust manifold: 33 ft. lbs. (45 Nm)
     
    Mounting bracket nuts: 18 ft. lbs. (25 Nm)
     
    Turbocharger outlet nuts: 18 ft. lbs. (25 Nm)
     
    Oil return line: 22 ft. lbs. (30 Nm)
     

  4.  


    Click image to see an enlarged view

    Fig. Exploded view of the intake and exhaust manifold, turbocharger and related components-1.9L (AHH) engine



    Click image to see an enlarged view

    Fig. Exploded view of the intake and exhaust manifold, turbocharger and related components-1.9L (AAA) engine



    Click image to see an enlarged view

    Fig. Exploded view of the intake and exhaust manifold, turbocharger and related components-1.9L (ALH) engine


1.8L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect:

    Negative battery cable
     
    Engine undercover, and unbolt the air conditioning compressor
     
    Turbocharger support bracket
     
    Oil return line at the turbocharger
     
    Air hoses from the turbocharger
     
    Oil feed line at the turbocharger
     
    Hose for the boost pressure regulation valve vacuum diaphragm
     
    Bracket for the coolant supply line at the boost pressure regulation valve vacuum diaphragm, and using Clamp 3094 or equivalent, pinch off the coolant supply hose
     
    Intake air duct between the cowl and the air cleaner housing
     
    Air cleaner housing cover
     

  4.  
  5. Label and detach the following lines and electrical connectors:

    Wastegate bypass regulator valve
     
    EVAP canister purge regulator valve
     
    Power outage stage
     
    MAF sensor
     

  6.  
  7. Remove or disconnect:

    Air cleaner housing and the engine cover
     
    Crankcase breather hose at the valve cover
     
    Oil supply line at the turbocharger
     
    Heat shield, and sleeve from the coolant return hose, and using Clamp 3094 or equivalent, pinch off the coolant return hose, then remove the hose.
     

  8.  


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



TWC from the turbocharger
 
Turbocharger from the exhaust manifold
 
Coolant supply banjo fitting
 
Turbocharger
 

To install:



Click image to see an enlarged view

Fig. exploded view of the turbocharger and related components-1.8L engine (AEB/ATW/AWV)



Click image to see an enlarged view

Fig. Exploded view of the hoses related to the turbocharger-1.8L engine (AEB/ATW/AWV)



Click image to see an enlarged view

Fig. exploded view of the turbocharger and related components-1.8L engine (AWP/AWW)



Click image to see an enlarged view

Fig. Exploded view of the hoses related to the turbocharger-1.8L engine (AWP/AWW)

  1. Install or connect:

    Turbocharger
     
    Coolant supply banjo fitting and tighten to 18 ft. lbs. (25 Nm)
     
    Turbocharger to the exhaust manifold, using new gaskets. Mounting bolts, coating the bolts with Hot Bolt Paste G 052 112 A3 (or equivalent): 26 ft. lbs. (35 Nm). Turbocharger support bracket mounting bolts: 33 ft. lbs. (45 Nm).
     
    TWC to the turbo
     
    Coolant supply hose
     
    Sleeve and heat shield to the return hose
     
    Oil return hose
     

  2.  
  3. Add oil to the turbocharger through the oil feed line.
  4.  
  5. Connect:

    Oil supply line to the turbocharger and tighten to 18 ft. lbs. (25 Nm).
     
    Crankcase breather, and install the engine cover and air cleaner housing.
     

  6.  
  7. Attach the following lines and electrical connectors:

    MAF sensor
     
    Power outage stage
     
    Wastegate bypass regulator valve
     

  8.  
  9. Install or connect:

    Hoses and brackets for the boost pressure regulation valve vacuum diaphragm.
     
    Air hoses to the air cleaner assembly and the turbo
     
    Air conditioning compressor and engine undercovers
     
    Coolant
     
    Negative battery cable
     

  10.  
  11. 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 turbocharger.
  12.  

  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.  


    Wastegate bypass regulator valve
     
    Evaporative Emission (EVAP) canister purge regulator valve
     
    Power outage stage
     
    Mass Air Flow (MAF) sensor
     

  27. Remove the air cleaner housing and the engine cover.
  28.  
  29. Disconnect the crankcase breather hose at the valve cover.
  30.  
  31. Disconnect the oil supply line at the turbocharger.
  32.  
  33. Remove the heat shield, and sleeve from the coolant return hose.
  34.  
  35. Using clamp Tool No. 3094, or equivalent, pinch off the coolant return hose, then remove.
  36.  


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.  



Click image to see an enlarged view

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



Click image to see an enlarged view

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



Click image to see an enlarged view

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.  


    Mass Air Flow (MAF) sensor
     
    Power outage stage
     
    Wastegate bypass regulator valve
     

  23. Connect the hoses and brackets for the boost pressure regulation valve vacuum diaphragm.
  24.  
  25. Connect the air hoses to the air cleaner assembly and the turbo.
  26.  
  27. Install the air conditioning compressor and engine undercovers.
  28.  
  29. 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.
  30.  
  31. Check the oil level and top off as necessary.
  32.  
  33. Connect the negative battery cable.
  34.  
  35. Enter the radio security code.
  36.  
  37. 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.
  38.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect:

    Negative battery cable
     
    Engine undercover, and unbolt the air conditioning compressor
     
    Turbocharger support bracket
     
    Oil return line at the turbocharger
     
    Air hoses from the turbocharger
     
    Oil feed line at the turbocharger
     
    Hose for the boost pressure regulation valve vacuum diaphragm
     
    Bracket for the coolant supply line at the boost pressure regulation valve vacuum diaphragm, and using Clamp 3094 or equivalent, pinch off the coolant supply hose
     
    Intake air duct between the cowl and the air cleaner housing
     
    Air cleaner housing cover
     

  4.  
  5. Label and detach the following lines and electrical connectors:

    Wastegate bypass regulator valve
     
    EVAP canister purge regulator valve
     
    Power outage stage
     
    MAF sensor
     

  6.  
  7. Remove or disconnect:
    WARNING
    The exhaust flexpipe may be damaged if bent more than 10 degrees.



    Air cleaner housing and the engine cover
     
    Crankcase breather hose at the valve cover
     
    Oil supply line at the turbocharger
     
    Heat shield, and sleeve from the coolant return hose, and using Clamp 3094 or equivalent, pinch off the coolant return hose, then remove the hose.
     



    TWC from the turbocharger
     
    Turbocharger from the exhaust manifold
     
    Coolant supply banjo fitting
     
    Turbocharger
     

  8.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the turbocharger and related components-1.8L engine (AEB/ATW/AWV)



Click image to see an enlarged view

Fig. Exploded view of the hoses related to the turbocharger-1.8L engine (AEB/ATW/AWV)



Click image to see an enlarged view

Fig. Exploded view of the turbocharger and related components-1.8L engine (AWP/AWW)



Click image to see an enlarged view

Fig. Exploded view of the hoses related to the turbocharger-1.8L engine (AWP/AWW)

  1. Install or connect:

    Turbocharger
     
    Coolant supply banjo fitting and tighten to 18 ft. lbs. (25 Nm)
     
    Turbocharger to the exhaust manifold, using new gaskets. Mounting bolts, coating the bolts with Hot Bolt Paste G 052 112 A3 (or equivalent): 271 inch lbs. (35 Nm). Turbocharger support bracket mounting bolts: 33 ft. lbs. (45 Nm).
     
    TWC to the turbo
     
    Coolant supply hose
     
    Sleeve and heat shield to the return hose
     
    Oil return hose
     

  2.  
  3. Add oil to the turbocharger through the oil feed line.
  4.  
  5. Connect:

    Oil supply line to the turbocharger and tighten to 18 ft. lbs. (25 Nm).
     
    Crankcase breather, and install the engine cover and air cleaner housing.
     

  6.  
  7. Attach the following lines and electrical connectors:

    MAF sensor
     
    Power outage stage
     
    Wastegate bypass regulator valve
     

  8.  
  9. Install or connect:

    Hoses and brackets for the boost pressure regulation valve vacuum diaphragm.
     
    Air hoses to the air cleaner assembly and the turbo
     
    Air conditioning compressor and engine undercovers
     
    Coolant
     
    Negative battery cable
     

  10.  
  11. 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 turbocharger.
  12.  

1.9L Diesel Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect:

    Negative battery cable.
     
    Exhaust pipe from the turbocharger outlet.
     
    Oil supply line and bracket, after cleaning the oil supply fitting on the top of the turbocharger.
     
    Inlet air hose.
     
    Oil return line and the turbocharger mounting bracket.
     
    Turbo-to-manifold bolts. Lift the turbocharger out from the top.
     

  4.  

To install:

  1. Installation is the reverse of removal. Before installing the oil supply line, fill the connection on the turbocharger with engine oil.
  2.  
  3. Tighten the following:

    Turbocharger-to-exhaust manifold: 33 ft. lbs. (45 Nm)
     
    Mounting bracket nuts: 18 ft. lbs. (25 Nm)
     
    Turbocharger outlet nuts: 18 ft. lbs. (25 Nm)
     
    Oil return line: 22 ft. lbs. (30 Nm)

    Click image to see an enlarged view

    Fig. Exploded view of the intake and exhaust manifold, turbocharger and related components-1.9L (AHH) engine



    Click image to see an enlarged view

    Fig. Exploded view of the intake and exhaust manifold, turbocharger and related components-1.9L (AAA) engine



    Click image to see an enlarged view

    Fig. Exploded view of the intake and exhaust manifold, turbocharger and related components-1.9L (ALH) engine

     

  4.  

 
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