Removing and installing connecting pipes: VW 2.0 TDI (CFCA)

Removing and installing connecting pipes
Special tools and workshop equipment required
Adjusting gauge
3371
Torque wrench
V.A.G 1331
Engine bung set
VAS 6122
Ratchet wrench 13 mm
T10384
Removing
Observe rules for cleanliness
Chapter
.
Assembly overview - charge-air hose connections
Chapter
Note
After lines and hoses have been removed, the open connections are to be sealed immediately with a plug from the
engine bung set
VAS 6122
.
Only use clean plugs.
Release and pull off connector
2
.
Unscrew bolts
1
.
The screw-type clip
2
is secured in the pressure hose
1
with
“barbs”
. Only the bolt has to be released.
Open screw-type clip
2
far enough to enable removal of delivery hose
1
from pulsation damper
3
.
Tie pressure hose
1
to one side.
Remove bolts
arrows
.
Unscrew bolt
1
from bracket
3
(beneath pipes) and remove connecting pipes
2
.
Only loosen nut
2
in order to be able to turn bracket
1
so that connecting pipes can be fitted.
Open clip
2
and pull off heat protection hose
1
.
Remove connecting/sealing pipe
arrow
.
Use brake cleaner to clean all sealing surfaces and contact surface for insulated hose.
Installing
Installation is carried out in the reverse order; note the following:
When turbocharger and connecting pipes are being assembled, it is essential that the correct repair set
Electronic Parts Catalogue
is used.
Apply a thin coat of
lithium grease
to sealing surfaces
arrows
of turbocharger
1
and connecting pipes
3
Electronic Parts Catalogue
Before fitting new O-ring
2
, apply a thin coat of
lithium grease
to O-ring and insert O-ring into turbocharger
Electronic Parts Catalogue
.
Insert new connecting/sealing pipe
arrow
into connecting pipe and press it in by hand to stop.
Fit new screw-type clip and new insulated hose loosely on turbocharger, but do not tighten.
Insert connecting pipes into the turbocharger without canting them. You must be able to hear and feel that connecting/sealing pipe
arrow
engages in turbocharger.
First, screw in new bolts
arrows
loosely.
Bolt
2
of bracket
1
must be loose.
Place connecting pipes
2
against bracket
3
and loosely screw in bolt
1
.
Press connecting pipes against bracket by hand and screw in bolts
arrows
only hand-tight.
Screw in bolt
1
only hand-tight.
Use
adjusting gauge
3371
to measure distance
a
between turbocharger and connecting pipes at three places. The distance
a
must measure 5 to 6 mm.
First tighten bolts
arrows
.
Then tighten bolt
1
.
Tighten nut
2
with
ratchet wrench 13 mm
T10384
.
Stretch new insulated hose
1
so that contact surfaces of turbocharger and connecting pipes are completely covered.
Fasten insulated hose
1
to connecting pipes with new screw-type clip
2
. Then pull insulated hose
1
down to turbocharger stops.
Specified torques
Chapter
“
Assembly overview - connecting pipes,
biturbo engine
”
Chapter
“
Assembly overview - turbocharger,
biturbo engine
”