Saturday, January 8, 2011

VW 2000 TDI,1.9l turbo charger disassembly.


Volkswagen Turbocharger Unit DisAssembly


Turbocharger Removal & Installation

Basic History And Understanding Of Turbocharger Unit

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.


Important 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.

Turbocharger Removal:
  1. Disconnect the negative battery cable. If equipped with an automatic transaxle, remove the starter.
  2. 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.
  3. Clean the oil supply fitting on the top of the turbocharger and remove the supply line and bracket.
  4. Remove the inlet air duct.
  5. Under the vehicle, remove the oil return line and the turbocharger mounting bracket.
  6. 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.

To install:
  1. If removed, install the exhaust manifold with a new gasket and torque the bolts to 18 ft. lbs. (25 Nm).
  2. 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).
  3. Use a new gasket and connect the oil return line. Torque the bolts to 22 ft. lbs. (30 Nm).
  4. Use a new gasket and connect the outlet pipe. Torque the nuts to 18 ft. lbs. (25 Nm).
  5. Connect the oil supply line, install the EGR valve.
  1. 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.

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. 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)




  3. VW Turbocharger in Exhaust manifold diagram

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


    removal of Intake manifold

    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