Assembly overview - turbocharger with exhaust manifold and attachments — VW

Assembly overview - turbocharger with exhaust manifold and attachments
Caution
Observe safety precautions when working on charge air system and turbocharger
Chapter
.
Observe rules for cleanliness
Chapter
.
Follow these instructions before starting work and while working on system.
Note
All hose connections are secured.
Charge air system must be free of leaks.
Renew self-locking nuts.
Before installing the turbocharger, fill the oil supply channel (smaller diameter) with a
»splash«
of engine oil
“to prevent a dry start up”
.
After installing turbocharger, run engine for about 1 minute at idling speed to ensure that oil is supplied to turbocharger.
Turbocharger
Can only be renewed together with exhaust manifold and vacuum unit.
Removing and installing
Chapter
Vacuum unit
With
position sender for charge pressure positioner
G581
.
Connector
To
position sender for charge pressure positioner
G581
.
Heat protection
Renew if damaged.
Gasket
Renew
20 Nm
Connecting pipe
To exhaust gas recirculation cooler.
Exhaust gas temperature sender 1
G235
, 45 Nm
Lubricate thread of sender using
high-temperature paste
G 052 112 A3
Note installation position
Fig.
.
Tighten to specified torque
Chapter
10 Nm
Bracket
Heat shield
10 Nm
Turbocharger support
Removing and installing
Chapter
.
Before installing oil supply line, ensure that it is not blocked.
Before installing the turbocharger, fill the oil supply channel (smaller diameter) with a
»splash«
of engine oil
“to prevent a dry start up”
.
O-rings
Renew
Banjo bolt, 60 Nm
Only replace together with O-rings.
O-rings
Renew
Banjo bolt, 30 Nm
Only renew complete with seals.
Seal
Renew
Oil supply line
Do not attempt to bend oil supply line to a different shape.
Install so that component is not stressed.
Removing and installing
Chapter
.
Before installing oil supply line, ensure that it is not blocked.
Before installing the turbocharger, fill the oil supply channel (smaller diameter) with a
»splash«
of engine oil
“to prevent a dry start up”
.
20 Nm
Pulsation damper
Note installation position of seals
Fig.
.
10 Nm
Installation position of O-ring and seal in pulsation damper
When installing seal
3
, ensure lug of seal
3
engages in groove of pulsation damper
1
.
Installation position of exhaust gas temperature sender with angled cable guide
Note
When the exhaust gas temperature sender with angled cable guide is being removed, the distance
a
of 3 ... 5 mm to screw support against turbocharger.