1.4 TSI engine (EA111) · Turbocharging/supercharging · Exhaust turbocharger

Removing and installing turbocharger

Special tools and workshop equipment required

  • Hose clamp pliers - VAS 6340-
  • Torque wrench - V.A.G 1331-

Removing

To prevent this from causing further damage, perform the following repairs:

  • Check air filter housing, air filter element and intake hoses for soiling.
  • Check complete charged air routing and charge air cooler for foreign objects.

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.

  • Disconnect battery ⇒ Electrical system; Rep. gr. 27; Disconnecting and reconnecting battery.
  • Lift engine cover panel at points -1- and pull it forwards in direction of -arrow-.
  • Unbolt heat shield over turbocharger -arrows-.
  • Open and close expansion tank cap to release pressure in cooling system.
  • Drain coolant (Golf Plus, Eos, Scirocco, Golf, Golf Cabriolet, Touran, Tiguan).
  • Drain coolant (Polo) ⇒ 1.6 Draining and filling coolant (Polo).
  • Drain coolant (Sharan).
  • Drain coolant (Passat, Passat CC).
  • Depending on vehicle equipment, remove noise insulation or skid plate ⇒ General body repairs, exterior; Rep. gr. 50; Removing and installing noise insulation or skid plate.
  • Remove radiator fan - V7- together with cowling ⇒ 3 Radiator, radiator fan.

Continued for all vehicles

  • Pull off connecting hoses -1- and coolant hoses -3-.
  • Unscrew bracket -2- and securing nuts -4- from turbocharger.
  • Unscrew securing bolt -2- and remove upper coolant pipe.
  • Unscrew bolts -1- and remove pressure pipe .

Passat, Passat CC

  • Remove cowling.
  • Remove catalytic converter.

Continued for all vehicles

  • Remove wiring for Lambda probe after catalytic converter - G130- and for alternator from cable guides -arrows-.
  • Pull connector off Lambda probe after catalytic converter - G130- and remove.
  • Open hose clip -3- and remove charge air pipe -2-.
  • Unbolt exhaust pipe from catalytic converter -arrows-.
  • Unbolt exhaust pipe to rear silencer -arrows-.
  • Loosen securing bolts of clamp -arrows- and pull exhaust pipe to rear.
  • Also pull out exhaust pipe together with flexible joint.
  • Remove catalytic converter together with charge air pipe downwards.

Removing poly V-belt (Tiguan).

Remove poly V-belt (Golf Plus, Eos, Scirocco, Golf, Golf Cabriolet, Touran, Polo, Sharan, Passat, Passat CC) ⇒ 1.3 Removing and installing poly V-belt (Golf Plus, Eos, Scirocco, Golf, Touran, Polo, Sharan, Passat, Passat CC, Golf Cabriolet).

  • Unscrew securing bolts for tensioning element -arrows- and remove it.
  • Remove upper alternator bolt and swing alternator out forwards.
  • Unscrew securing bolt -arrow- for oil return pipe -2- from turbocharger.
  • Pull oil return pipe downwards.
  • Unbolt charge air hose -1- from turbocharger.
  • Unscrew banjo bolts of oil supply pipe -arrows- from turbocharger and valve timing housing.
  • Remove oil supply pipe.
  • Unscrew all securing nuts from exhaust manifold -1-.
  • Pull exhaust manifold out upwards with turbocharger.

Installing

Installation is carried out in the reverse order. When installing, note the following:

  • Renew studs and fastening nuts.
  • Screw the studs into cylinder head until they project only 25 mm.
  • Coat studs with high-temperature paste.
  • Observe tightening sequence and specified torques: items
  • Renew seals, gaskets and self-locking nuts.
  • Fill turbocharger with engine oil at oil supply line connection.
  • After installing turbocharger, run engine for about 1 minute at idling speed to ensure that oil is supplied to turbocharger.
  • Hose connections and hoses for charge air system must be free of oil and grease before assembly.
  • Secure all hose connections with hose clips which conform to production standard.
  • Install exhaust system and align it free of stress.
  • When installing air pipes with plug-in connector, ensure that securing clip -arrow- audibly engages into retaining lug -A-.

Fitting hose connections with plug-in connectors ⇒ 3.4 Fitting hose connections with plug-in connectors

Specified torques:

Assembly overview - turbocharger ⇒ 1.1 Assembly overview - turbocharger.

Assembly overview - charge air system (Eos, Golf Plus, Golf, Golf Cabriolet, Touran, Scirocco, Tiguan, Sharan)

Assembly overview - charge air system (Polo) ⇒ 3.2 Assembly overview - charge air system (Polo)

Assembly overview - charge air system (Passat, Passat CC)

Assembly overview - catalytic converter and add-on parts ⇒ 26 – Exhaust system

Install alternator ⇒ Electrical system; Rep. gr. 27; Removing and installing alternator.

  • Push engine cover panel down at points -1- in direction of -arrow- until it engages.