Assembly overview - turbocharger, “single turbo engine” — VW

Assembly overview - turbocharger,
“single turbo engine”
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 screwing on oil supply line, fill turbocharger at connection with engine oil.
After installing turbocharger, run engine for about 1 minute at idling speed to ensure that oil is supplied to turbocharger.
Connecting pipe
To exhaust gas recirculation cooler.
Nut
20 Nm
Gasket
Renew after removing
Seal
Renew after removing
Connector
Exhaust gas temperature sender 1
G235
Only fitted on 84, 100 and 103 kW engines.
Grease thread of sender using
high-temperature paste
Electronic Parts Catalogue
.
Sender must not be bent when removing and installing.
Sender must not contact any other component on installation.
45 Nm
Plug
Only fitted in 62 and 75 kW engines.
Grease thread of plug using
high-temperature paste
Electronic Parts Catalogue
.
45 Nm
Turbocharger
Must only be renewed together with exhaust manifold and
position sender for charge pressure positioner
G581
.
Note tightening sequence and installation procedure
Fig.
.
Removing and installing
Chapter
Nut
Renew after removing
Observe tightening sequence and procedure
Fig.
25 Nm
Screw-type clip
5.5 Nm
Intake hose
Installation position
Fig.
Pipe assembly
Do not separate connector for pipe/hose assembly.
Caution
Note procedure for separating and connecting pressure hose
Item
under all circumstances
Chapter
.
Connecting hose
Do not separate connector for pipe/hose assembly.
Caution
Note procedure for separating and connecting pipe
Item
under all circumstances
Chapter
.
Note installation position of connecting hose
Fig.
.
Screw-type clip
5.5 Nm
Bolt
10 Nm
Pulsation damper
Gasket
Renew if damaged or leaking
Support ring
Renew if damaged or leaking
Installation position in pulsation damper
Anchor
.
Support
When installing turbocharger, support must be released on crankcase and turbocharger.
Bolt
20 Nm
Seal
Renew after removing
Oil return pipe
After installing oil supply pipe, ensure that it is not blocked.
Bolt
15 Nm
Spring-type clip
Hose clip pliers
VAS 6340
or
hose clip pliers
VAS 6362
are recommended for installation of spring-type clips.
Oil return hose
After installing oil return hose, ensure that it is not blocked.
Bolt
23 Nm
Heat shield
Note
One of two different heat shields are fitted and this depends on equipment installed.
Only one is available as a replacement part.
Regulating flap potentiometer
G584
Removing and installing
Chapter
Bolt
25 Nm + 90°
Screw-type clip
8 Nm
Seal
Renew after removing
Banjo bolt
Renew after removing
30 Nm
Seal
Renew after removing
Oil supply line
Before installing oil supply line, ensure that it is not blocked.
Before installing, fill turbocharger with engine oil through oil supply line connection.
Seal
Renew after removing
Bolt
10 Nm
Screw-type clip
Union nut
22 Nm
Tightening sequence and procedure
Support
Item
must be released on crankcase and turbocharger.
Position turbocharger
Item
on studs on cylinder head.
Only screw bolt 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
.
Tighten bolt
Item
.
Installation position of intake hose at turbocharger
Fit connecting hose in such a way that the
“extension”
2
of the connecting hose is in contact with the corner of the nameplate
2
.
Installation position of connecting hose
Install connecting hose in such a way that marking
1
on connecting hose is opposite marking
2
on pulsation damper.
Installation position of O-ring and seals in pulsation damper
Damper
With grooves
O-ring
Seal
With spring