1.2 TDI CR engine (EA189) · Turbocharging/supercharging · Turbocharger

Removing and installing turbocharger

Special tools and workshop equipment required

  • Tool insert, AF 17 mm - T10395-
  • Transport lock - T10403-
  • Torque wrench - V.A.G 1331-
  • Used oil collection and extraction unit, e.g. -V.A.G 1782-

If foreign objects are found in the charge air system, the charged air routing must be cleaned and the charge air cooler must be renewed, if necessary.

⇒ 2 Safety information

⇒ 3.1 Rules for cleanliness

»Carry out the following work sequence«

Removing

  • With ignition switched off, disconnect battery earth strap. ⇒ Electrical system; Rep. gr. 27; Disconnecting and reconnecting batteries.
  • Remove engine cover panel ⇒ 3 Engine cover panel.
  • Pull connector -1- off position sender for charge pressure positioner - G581- on turbocharger.
  • Remove connecting hose -2-.
  • Unscrew bolt -3- (attached) and screw intake hose clockwise out of its bracket.
  • Remove air filter housing with air mass meter and connecting pipe ⇒ 7.1 Assembly overview - air filter.
  • Remove plenum chamber bulkhead ⇒ General body repairs; Rep. gr. 50; Body - front; Plenum chamber bulkhead.
  • Pull off vacuum hose on turbocharger.
  • Loosen upper charge air pipe.
  • Loosen clamp -1- on connecting hose to pulsation damper.
  • Remove pulsation damper together with connecting hose.

Loosen particulate filter.

  • Remove securing clamp -1- between particulate filter and turbocharger.
  • Loosen bolt -2- and remove clamp.
  • Disconnect connector -3-.
  • Unscrew bolt -2-, remove pressure differential sender - G505-, free hoses -1-.
  • Remove connecting pipes -A-.
  • On flexible joint in front exhaust pipe, fasten the transport lock - T10403- -arrow-.
  • Unscrew bolts -1- and nuts -2-, remove bracket for particulate filter.
  • Loosen securing bolts -arrows- of clamping sleeve, then push down backwards from front exhaust pipe.
  • Move particulate filter to side and fix using suitable means.

It must not be bent.

It must therefore be removed.

  • Remove exhaust temperature sender 1 - G235- -1-.
  • Unscrew bolts -arrows- and remove heat shield.
  • Unscrew nuts -arrows- and pull turbocharger with exhaust manifold off cylinder head.
  • Carefully remove turbocharger from above in direction of gearbox.

Installing

  • Install in reverse order. During this procedure, observe the following:

Specified torques: Turbocharger ⇒ 21 – Turbocharging/supercharging.

Specified torques: Oil supply line and oil return line (turbocharger support) ⇒ 4 Oil circuit.

Specified torques: Connecting pipes ⇒ 3 Exhaust gas recirculation.

  • Position connecting hose of charge air pipe before bolting on turbocharger.
  • Note installation position of exhaust temperature sender 1 - G235-.

Installation position of exhaust gas temperature sender with angled cable guide

1.2.1 Tightening exhaust gas temperature sender 1 - G235-

Extending the torque wrench - V.A.G 1331- with the spanner from tool set - T10395/7- allows the correct torque of 45 Nm to be achieved.

Lubricate thread of sender using high-temperature paste - G 052 112 A3-.

  • Screw exhaust temperature sender 1 - G235- in by hand.
  • Then apply tightening torque using torque wrench - V.A.G 1331- together with wrench from tool set - T10395/7-.