Volkswagen Golf Service & Repair Manual: Removing and installing turbocharger
| Special tools and workshop equipment
required |
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| Engine bung set -VAS 6122- |
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| Hose clip pliers -VAS 6362- |
 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. |
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Unscrew bolts -arrows- and
remove heat shield for right drive shaft. |
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| – |
Remove heat-shield sleeve. |
| – |
Disconnect connector -arrow-
from oil pressure switch for reduced oil pressure -F378-. |
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Remove bolts -arrows- and
detach oil supply line -1- and oil
return line -2-. |
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| – |
Unscrew bolt -2- and remove
screw-type clip. |
| – |
Remove bolt -1- and nuts
-arrows- and tie up catalytic
converter. |
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| – |
Release hose clips -1- and
-2-, and remove air pipe. |
| – |
Move air hoses clear at air pipe. |
| – |
Detach connector from charge pressure sender -GX26-. |
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| – |
Release fasteners -arrows-
using release tools -T10527- and -T10527/1-. |
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| – |
Press release tabs and disconnect hose
-1- for activated charcoal filter. |
| – |
Remove bolts -arrows- and
detach crankcase breather hose. |
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| – |
Disconnect electrical connector -2-. |
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Remove bolts -arrows- and
detach connection -1-. |
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| – |
Release hose clip -2- and
detach coolant hose. |
| – |
Remove bolts -arrows- and pivot
coolant lines -1- to right side. |
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| – |
Unscrew bolts -arrows- and
remove heat shield -1-. |
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| – |
Unscrew nuts -arrows- and
remove turbocharger. |
| Installation is carried out in the reverse order; note the
following: |
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| – |
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. |
| → 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 |
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1 -
Turbocharger
Removing and installing
→ Chapter
2 -
Bolt
8 Nm
3 - ...
Removing
–
Switch off ignition.
–
Disconnect electrical connecto ...
Other materials:
Test preparations, wheel alignment with no driver assist systems
Special tools and workshop equipment required
Wheel alignment computer -V.A.G 1813F- or VW/Audi-approved wheel
alignment units
Brake pedal depressor -V.A.G 1869/2-
Tool insert 18 mm -T10179-
Shock absorber set ...
Folding the backrests on the rear bench seat forwards and backwards
Fig. 95 Rear bench seat: release button
①; red marking ②
First read and observe the introductory information
and safety warnings The rear seat is split for folding. Each part of the
rear bench seat can be folded down to increase the size of the luggage compartment.
Folding the rear ...
Removing and installing window winder
Removing
–
Slide spacer ring -2- in
-direction of arrow a- and pull window
winder off window lifter mechanism -arrow b-.
Installing
–
Slide on spacer and press window winder onto window lifter
mechanism.
...
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Assembly overview - turbocharger
Removing and installing charge pressure positioner -V465-