Removal and installation of a turbocharger on the engine «AFN»

To remove, put the instrument and starter switch key in position «Turned off». Disconnect the wire from the negative battery terminal. Remove the protective tray of the engine compartment. Remove the charge air line connecting the turbocharger to the turbocharger air/air heat exchanger and the intake air line from the air filter to the turbocharger. Disconnect the oil supply line from the turbocharger, remove the clamp securing the turbocharger to the intake manifold. Disconnect the exhaust pipe from the turbocharger. Remove the turbocharger-to-cylinder block mounting bracket. Disconnect the oil drain line from the turbocharger.

Unscrew the nuts of the lower mounting studs from below and the nut of the upper stud securing the turbocharger to the exhaust manifold from above and remove the turbocharger through the top.

To install, apply Volkswagen G 000 500 heat-resistant grease to the threads of the turbocharger and exhaust manifold studs. Install the turbocharger on the exhaust manifold and screw on the nut of the upper mounting stud. Screw in the nuts of the lower turbocharger mounting bolts and tighten them to a torque of 2.5 kgf·m. Attach an oil drain pipe with a new gasket to the turbocharger and tighten its fastening bolts to a torque of 3.0 kgf·m. Install the turbocharger mounting bracket to the cylinder block and tighten its M8 bolts to a torque of 2.5 kgf·m, and the M10 bolts to a torque of 3.0 kgf·m. Tighten the nut of the upper turbocharger mounting stud to a torque of 2.5 kgf·m.


Attach the exhaust pipe of the mufflers with a new gasket to the turbocharger and tighten the nuts of the fastening studs to a torque of 2.5 kgf·m. Pour oil into the turbocharger through the oil inlet pipe. Connect the oil supply line and tighten its fastening fitting to a torque of 2.5 kgf·m. Tighten to 1.0 kgf·m the nuts of the bolts securing the oil supply line bracket. Install a new gasket on the intake air duct and tighten the bolts of its fastening to the turbocharger and intake piping to a torque of 1.0 kgf·m.

Connect the vacuum hose to the boost pressure control valve and the air/air heat exchanger. Connect the air line connecting the turbocharger to the air filter.

Disconnect the charge air line connecting the air/air heat exchanger of the turbocharging system to the intake manifold. Disconnect the vacuum hose from the EGR valve.

Connect the hand vacuum pump hose to the valve. By creating a vacuum with a hand vacuum pump, watch the valve diaphragm stem, which should move in the direction of the arrow (pic. 3-61). Disconnect the hand vacuum pump hose from the valve. In this case, the valve stem must move in the direction opposite to that shown by the arrow.

Note. After installing the turbocharger, start the engine and let it idle for about 1 minute to restore oil circulation through the turbocharger bearings, and only after that the engine can be operated in operating conditions.

Details of the turbocharging system are shown in fig. 3-60.