VW Golf manuals

Volkswagen Golf Service & Repair Manual: Removing and installing turbocharger

Special tools and workshop equipment required
   
Engine bung set -VAS 6122-
 

Removing and installing turbocharger

Hose clip pliers -VAS 6362-
Release tool -T10527-
Release tool -T10527/1-
Removing
  Note
Observe rules for cleanliness → Chapter.
Fit all heat shield sleeves in the same place when installing.
If a mechanical fault is discovered on the turbocharger (e.g. a destroyed compressor impeller), it is not sufficient to just renew the turbocharger. To avoid any subsequent damage, the following work must be carried out:
Check air filter housing, air filter element and air inlet hoses for contamination.
Check the whole charge air path and charge air cooler for foreign objects.
If foreign objects are discovered in the charge air system, clean the charge air path and, if necessary, renew the charge air cooler.
–  Drain coolant → Chapter.
 

Removing and installing turbocharger

–  Unscrew bolts -arrows- and remove heat shield for right drive shaft.
 

Removing and installing turbocharger

–  Remove heat-shield sleeve.
–  Disconnect connector -arrow- from oil pressure switch for reduced oil pressure -F378-.
 

Removing and installing turbocharger

–  Remove bolts -arrows- and detach oil supply line -1- and oil return line -2-.
  Removing and installing turbocharger
–  Unscrew bolt -2- and remove screw-type clip.
–  Remove bolt -1- and nuts -arrows- and tie up catalytic converter.
 

Removing and installing turbocharger

–  Release hose clips -1- and -2-, and remove air pipe.
–  Move air hoses clear at air pipe.
–  Detach connector from charge pressure sender -GX26-.
 

Removing and installing turbocharger

–  Release fasteners -arrows- using release tools -T10527- and -T10527/1-.
–  Remove air pipe -1-.
 

Removing and installing turbocharger

–  Press release tabs and disconnect hose -1- for activated charcoal filter.
–  Remove bolts -arrows- and detach crankcase breather hose.
 

Removing and installing turbocharger

–  Disconnect electrical connector -2-.
–  Remove bolts -arrows- and detach connection -1-.
 

Removing and installing turbocharger

–  Release hose clip -2- and detach coolant hose.
–  Remove bolts -arrows- and pivot coolant lines -1- to right side.
 

Removing and installing turbocharger

–  Unscrew bolts -arrows- and remove heat shield -1-.
 

Removing and installing turbocharger

–  Unscrew nuts -arrows- and remove turbocharger.
Installing
Installation is carried out in the reverse order; note the following:
 

Removing and installing turbocharger

–  Fit screwdriver -2- in recess -arrow- on turbocharger and lever out seal -1-.
  Note
Renew seals, O-rings and securing nuts of cylinder head.
Renew clamps for attaching catalytic converter to turbocharger.
Fill turbocharger with engine oil at connection for oil supply line.
Secure all hose connections with hose clips meeting production standard → Electronic Parts Catalogue.
After installing turbocharger, run engine for about 1 minute at idling speed to ensure that oil is supplied to turbocharger.
–  Electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations.
–  Replenish coolant → Anchor.
Specified torques
→ Chapter „Assembly overview - turbocharger“
→ Fig. „“Installing air ducts with screw-type clips”“
→ Fig. „“Installing catalytic converter - tightening torque and sequence”“
→ Running gear, axels, steering; Rep. gr.40
 

Removing and installing turbocharger

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Removing and installing charge pressure positioner -V465-
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