turbocharger removal

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2007 Volkswagen GTI L4-2.0L Turbo (BPY)

Vehicle Level Powertrain Management Fuel Delivery and Air Induction Turbocharger Service and Repair Removal and Replacement Turbocharger, Removing and Installing

Turbocharger, Removing and InstallingNotes

Turbocharger, Removing And Installing Special tools, testers and auxiliary items required

� Spring-type clip pliers VAS 5024 A

� Tensioning Strap T10038

CAUTION: If mechanical damage is found on exhaust turbocharg er, e.g. a destroyed compression wheel, it is not enough to just replace the turboch arger. Perform the following steps to prevent subsequent damage.

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� Check air filter housing, the air filter insert and intake hoses for contamination. � Check entire charge air circuit and cooler for cont amination. If contaminants are

found in charge air circuit, circuit must be cleane d and cooler replaced if necessary.

Removing:

� Remove engine cover/air filter and remove intake hose from turbocharger. � Drain coolant.

� Remove right front part of wheel housing liner.

� Remove charge air hose -arrow- from charge air cooler.





� Remove bolts -arrows- and disconnect charge air pipe.

� Remove connector - 1 and 2 - and unclip cable. � Remove bolts -arrows- and remove connection from turbocharger.

� Disconnect Heated Oxygen Sensor (HO2S) G39 harness connector -arrow- and expose cable.






� Disconnect connectors from ignition coils and set wiring harness aside.

� Disconnect coolant line to coolant expansion tank -arrow-.

� Disconnect coolant hoses -1- and -2-. � Remove coolant line -3-.






� Disconnect upper coolant hose from heater core -arrow-.

� Remove shielding plate with coolant pipe -arrows-.

� Remove line for crankcase ventilation with heat shield from turbocharger -1-. � Disconnect line for crankcase ventilation from cylinder head cover -2- and remove it. � Disconnect EVAP canister line to turbocharger from cylinder head cover -3-. � Loosen oil supply line at turbocharger -4-.






� Remove both upper mounting nuts of front exhaust pipe/turbocharger.

� Remove heat shield for right drive axle -arrows-.

� Remove both lower mounting nuts of front exhaust pipe/turbocharger.






� Remove bracket for exhaust system -arrows-.

� Disconnect exhaust system at clamping sleeve -arrows-. � Disconnect front exhaust pipe from turbocharger and slide it toward rear slightly.

NOTE : Catalytic converter is not removed and oxygen sensor connector is not disconnected.

� Remove oil supply line and coolant supply line at turbocharger -arrows-.






� Disconnect oil return line -arrows- from turbocharger.

� Remove bolts -1- and -2- and remove support for turbocharger.

NOTE: The following work step is necessary to achieve some more room between cylinder head and bulkhead.

� Remove bolts - 2 and 3 -.






� Pull engine approx. 20 mm toward rear using Tensioning Strap T10038.

� Disconnect coolant pipe -arrow-.

NOTE:

� Retaining strip nuts do not have to be loosened. � Bolt -1- is installed only on coolant pipes with two brackets.






� Remove bolt -1- for coolant pipe and remove top nuts -arrows-. � Remove turbocharger/exhaust manifold upward.

Installing : CAUTION: If mechanical damage is found on exhaust turbocharg er, e.g. a destroyed compression wheel, it is not enough to just replace the turboch arger. Perform the following steps to prevent subsequent damage.

� Check air filter housing, the air filter insert and intake hoses for contamination. � Check entire charge air circuit and cooler for cont amination.

If contaminants are found in charge air circuit, ci rcuit must be cleaned and cooler replaced if necessary. Installation is in reverse order of removal, note the following:

� Assembly of hose connections with connection couplings. � Always replace seals, gaskets and self-locking nuts. � Add oil to turbocharger through oil feed line connecting piece. � After installing turbocharger, let engine idle for approx. 1 minute to ensure adequate oil

supply to the turbocharger. � Hose connections and charge air system hoses must be free of oil and grease before

installing. Sealing ring and sealing surfaces must only be lightly oiled with connector couplings.

� Secure all hose connections using hose clamps appropriate for the model type.

Pendulum supports to transmission Exhaust manifold/turbocharger to

Oil supply line to exhaust

Oil return line to exhaust

Coolant supply line to

Component Nm

cylinder head 20 1)

turbocharger 30

turbocharger 9

turbocharger 35

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Bracket for turbocharger to

Turbocharger bracket to

Right charge air pipe

1) Replace nuts 2) Use hot bolt paste

cylinder block 30 2)

turbocharger 30 2)

to oil pan 10

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