Assembly overview - turbocharger, bi-turbo — VW

Assembly overview - turbocharger, bi-turbo
Note
Sealed bolts and nuts must not be loosened.
All hose connections are secured.
Charge air system must be free of leaks.
Renew self-locking nuts.
Before securing the oil pressure line, fill turbocharger with engine oil through connecting piece.
After installing turbocharger, allow engine to run at idling speed for about 1 minute to ensure that oil is supplied to turbocharger.
Exhaust manifold with turbocharger
Renew complete unit only.
Removing and installing
Chapter
.
If the oil return line is separated at the hose clip
Item
or if it is damaged, the hoses of the oil return line must be renewed.
Check oil supply lines for damage before installing them.
Note tightening sequence and installation procedure
Fig.
.
When turbocharger and connecting pipes are being assembled, it is essential that the correct repair set
Electronic Parts Catalogue
is used.
Exhaust gas temperature sender 1
G235
Lubricate thread of sender using
high-temperature paste
Electronic Parts Catalogue
.
Exhaust temperature sender 1
G235
must not be bent or twisted when removing and installing.
Exhaust temperature sender 1
G235
must not contact any other component on installation.
45 Nm
Nut
Renew after removing.
24 Nm
Tightening sequence
Fig.
.
Procedure for dismantling and assembling:
Position turbocharger on studs on cylinder head.
Tighten turbocharger bolts in specified tightening sequence
Fig.
.
Initially, tighten nut hand-tight, then tighten it completely. Then tighten bolts again to prescribed torque.
Gasket
Renew after removing.
Bracket
Banjo bolt
30 Nm
Double seal
Remember that there are various sizes
Renew after removing.
Banjo bolt
24 Nm
Oil supply line
For complete removal of the oil supply line, the engine supports and the starter must first be removed.
Note
Risk of damage when removing and installing turbocharger.
Check oil supply line for damage after removing (kinks in hose). Oil supply line must be renewed if damaged.
Check oil supply line for damage (kinks in hose) after installing turbocharger.
Removing and installing
Chapter
Banjo bolt
40 Nm
Seal
Renew after removing.
Bolt
25 Nm
Bolt
40 Nm
Bolt
Renew after removing.
40 Nm
Caution
Note tightening sequence and procedure when bolting turbocharger on.
Tightening sequence and procedure
Fig.
.
Banjo bolt
60 Nm
Oil return line
Note
If the oil return line is separated at the hose clip
Item
or if it is damaged, the hoses of the oil return line must be renewed.
The turbocharger is delivered with a new oil return line. When renewing the turbocharger, always use the new oil return line for the turbocharger.
Bolt
11 Nm
Gasket
Renew after removing.
Clip
Oil return line
Note
If the oil return line is separated at the hose clip
Item
or if it is damaged, the hoses of the oil return line must be renewed.
The turbocharger is delivered with a new oil return line. When renewing the turbocharger, always use the new oil return line for the turbocharger.
Bolt
15 Nm
Banjo bolt
30 Nm
Line to
charge pressure sender 2
G447
Retaining clamp
Bolt
9 Nm
Bolt
3 Nm
Charge pressure sender 2
G447
Tightening sequence and installation procedure
Position exhaust manifold together with turbocharger on studs on cylinder head.
Only screw bolt
Item
loosely into turbocharger.
Tighten nuts
1
to
8
to 25 Nm in specified sequence. Then tighten nuts to 25 Nm again in specified sequence.
Tighten bolt
Item
.