Turbocharger removal: VW 2.0 TDI (CFFB, CFHB, CFHC, CLCA, …)

🧭 Before you start

Fits: VW Jetta VI (16, 2010–2018), VW Golf V / Jetta (1K, 2003–2009)

• Special tools named: T10422
• Renewed: nuts

Don't miss

• When detaching the oil supply line, counterhold the connection. Risk of damage as a consequence! — Prepare a 14 mm open-ended wrench for counterholding.
• Counterhold union with open-jaw wrench AF 14 and unscrew oil supply line (arrow) on turbocharger with socket T40055.
• Counterhold lock nut (B) with ring spanner T10423 and unscrew securing nut (A) from the control rod using socket inset T10422.
• Make sure that the guiding element moves easily along the control rod.
• Counterhold locknut(B) and screw securing nut(A) onto the control rod towards the adjusting lever. Tighten slightly with ring spanner T10423.

🔧 Engine codes this applies to

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. ⚠ The special tools indicated, in particular the socket inset,T10422 is designed solely for use according to the following work instructions and must not be used for other threaded connections. There is a danger of deformation if high torques are applied. — Remove air filter housing with air mass meter and connecting pipe (see the separate procedure).
2. Open heat-protection mat and disconnect electrical connector (arrow) at position sender for charge pressure positioner G581.
3. Remove crankcase breather connecting pipe(1) from cylinder head cover; press release buttons to do this.
4. Free vacuum hoses (arrows).
5. Unscrew bolt (2) (captive), swing air pipe with inlet connection to rear and pull off from turbocharger.

6. Seal opening in turbocharger with sealing cap from replacement parts kit.
7. Unscrew bolt (1) and remove hot air pipe from guide (2).
8. Pull off vacuum line at turbocharger.
9. Unscrew securing nut (arrow) where the oil supply line/vacuum line is connected to the cylinder head.
10. ⚠ When detaching the oil supply line, counterhold the connection. Risk of damage as a consequence! — Prepare a 14 mm open-ended wrench for counterholding.
11. Counterhold union with open-jaw wrench AF 14 and unscrew oil supply line (arrow) on turbocharger with socket T40055.
12. Seal oil supply opening in turbocharger with plug from replacement parts kit.
13. Modify socket T10422 to dimension (A).
14. Position ring spanner T10423(1) and socket T10422(2) with reversible ratchet(3) as shown.
15. Counterhold lock nut (B) with ring spanner T10423 and unscrew securing nut (A) from the control rod using socket inset T10422.
16. Unscrew securing bolts of the vacuum unit (arrows) and remove the vacuum unit (A).
17. ⚠ Only use new nuts and bolts from replacement parts kit! — If necessary, remove lower securing nut of the control rod from the new vacuum unit.
18. Screw locknut by hand onto the control rod as far as possible in the direction of the vacuum unit.
19. Push control rod through the adjusting lever, fit vacuum unit (A) and tighten fastening bolt.
20. Tighten securing bolts (arrows) to 8 Nm. [Note: Make sure that the guiding element moves easily along the control rod.] — 8 Nm (5.9 lb-ft)
21. Remove protective cap, fit oil supply line to turbocharger and tighten to 22 Nm. — 22 Nm (16 lb-ft)
22. Fit connector (arrow) to position sender for the charge pressure servo G581 and close heat protection mat.
23. Connect vehicle diagnosis tester.
24. Click the "“Vehicle self-diagnosis”" button on the display.
25. Click the "“01 - Engine electronics”" button on the display.
26. Click the "“011 - Measured values”" button on the display.
27. Use the numeric keypad to enter the block of measured values "“120”" and acknowledge entry with the "“Q”" key.
28. Connect hand vacuum pump VAS 6213 to vacuum unit.
29. Observe the lowest value of the measured value block and set a voltage of 0.760 V by causing a partial vacuum.
30. ⚠ During the following procedure for adjusting the control rod, keep the partial vacuum and thus the voltage of 0.760 V constant. — Slowly screw the locknut(B) of the control rod downwards by hand. Adjusting lever is resting on the lower »stop«.
31. Counterhold locknut(B) and screw securing nut(A) onto the control rod towards the adjusting lever. Tighten slightly with ring spanner T10423.
32. Allow partial vacuum to escape from the vacuum unit.
33. Observe the lowest value of the measured value block. When there is no pressure, the value should be 3.30 to 3.90 V.
34. Fit socket inset T10422, counterhold locknut (B) with ring spanner T10423 and tighten securing nut (A).
35. ⚠ Cause a partial vacuum of 0.75 ± 0.05 bar to act on the vacuum unit in order to ensure that the adjusting lever rests against the »stop«. When this is done, the voltage should automatically be set to 0.760 V. — Press locking plate by hand onto the control rod and turn 90° in the (direction of the arrow).
36. Seal connection between control rod/securing nut with sealing paint from replacement parts kit.
37. Counterhold locknut (B), undo securing nut (A) of the control rod and correct the voltage by turning the locknut (B).
38. Counterhold locknut (B), turn securing nut (A) in opposing direction and tighten it with socket inset T10422.
39. Press locking plate by hand onto the control rod and turn 90° in the (direction of the arrow).
40. Seal connection between control rod/securing nut with sealing paint from replacement parts kit.
41. Fit securing nut (arrow) connecting the oil supply line/vacuum line to the cylinder head and tighten it.
42. Remove sealing cap from turbocharger.
43. Complete the engine.
44. Start motor and erase fault memory
45. Check setting as follows:
46. Click the "“006 - Basic setting”" button on the display.
47. Use the numeric keypad to enter the block of measured values "“120”" and acknowledge entry with the "“Q”" key.
48. Click the "“Activate”" button in the lower half of the screen.
49. Observe the value in the lower screen window; it must fluctuate between 0.65 ... 0.85 and 3.30 ... 3.90 V (vacuum unit is move to both end stops alternately).
50. End basic setting procedure.

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