Removing and installing exhaust manifold gasket: VW 2.0 TDI (CFCA)

Removing and installing exhaust manifold gasket
Note
The turbocharger does not have to be removed completely to remove and install the gasket.
Use a commercially available stud extractor to remove the two studs from the 1st cylinder.
Note the installation location of the studs.
Special tools and workshop equipment required
Torque wrench
V.A.G 1331
Torque wrench
V.A.G 1332
Torque wrench
V.A.G 1410
Engine bung set
VAS 6122
In order to remove the gasket, the
“biturbo”
has to be
»divided«
in two. The upper part of the intake pipes with the pulsation damper must be removed upwards. The
“biturbo”
is removed downwards and placed aside.
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.
Remove any noise insulation
General body repairs, exterior
Rep. gr.
66
Noise insulation
.
Remove connecting pipe
Chapter
Release and detach connector
arrow
of
exhaust temperature sender 1
G235
. Then, lay wiring harness to one side.
Pull lines
2
,
3
and
4
out of mounting for intake hose
1
.
Open screw-type clip
5
wide enough to enable removal of intake hose
1
.
Unscrew bolt
2
and remove from clamp
1
.
Loosen particulate filter
3
.
Vehicles with four-wheel drive
Disconnect catalytic converter.
Continuation for all vehicles
Unscrew nuts
arrows
above and to right of turbocharger.
Unscrew nuts
arrows
above and to left of turbocharger.
Front-wheel drive vehicles: removing particulate filter
Chapter
.
Four-wheel drive vehicles: catalytic converter
Chapter
.
Unscrew bolts
1
and remove bracket
2
.
Unscrew bolt
1
from support mounting
3
.
Unscrew bolts
2
and bolt
3
and remove rear torque reaction support
1
.
Unscrew bolt
2
of oil supply line
3
.
Caution
Oil supply line
3
must not be kinked when removing and installing.
Oil supply line
3
must be checked for damage after removing.
Notes on checking
Item
.
Unscrew bolt
4
and use a cloth to soak up any escaping oil.
Pull hose
1
off vacuum unit
2
.
Release connector
1
and pull off from
regulating flap potentiometer
G584
.
Pull hose
2
off
regulating flap potentiometer
G584
3
.
Unscrew nuts
arrows
below and to the right of the turbocharger.
Unscrew nuts
arrows
below and to the left of the turbocharger.
Unscrew union nut
4
of oil return line
3
. When doing this, counterhold on connection
5
.
Remove bolt
1
from bracket
2
.
Caution
Avoid damage to oil supply line
Item
. Observe notes.
When doing this, ensure that no pressure is exerted on the linkage.
Do not hold onto the rod when removing the turbocharger.
When carrying the turbocharger, always hold it by the pipes and not by the rod.
Bent linkage will impair the function of the turbocharger.
Cover anti-roll bar with a cloth or similar to avoid damage to paintwork.
Remove turbocharger and carefully place aside.
Once turbocharger has been placed aside, bolt
2
must be released from bracket
1
for reinstalling.
Note information on oil return line
Item
.
WARNING
The gasket has very sharp edges. Always wear gloves.
Remove gasket from studs between turbocharger and cylinder head.
Renew studs.
Note
Use a commercially available stud extractor to remove the two studs from the 1st cylinder.
Note the installation location of the studs.
Installing
Installation is carried out in the reverse order; note the following:
Renew seals, gaskets and self-locking nuts.
Clean sealing surfaces.
When turbocharger and connecting pipes are being assembled, it is essential that the correct repair set
Electronic Parts Catalogue
is used.
Fit new double seal
2
onto the respective line connection
1
and secure by screwing in the corresponding banjo bolt
3
.
Bolt
2
must be released from bracket
1
for reinstalling.
Only screw bolt
1
loosely into bracket
2
.
Caution
Note tightening sequence and procedure when bolting turbocharger on
Fig.
.
Oil supply line
3
must be checked for damage after installing.
Notes on checking
Item
.
Install connecting pipes
Chapter
.
Specified torques
Chapter
“
Assembly overview - turbocharger,
biturbo engine
”
Chapter
“
Assembly overview - exhaust gas recirculation
”
Chapter
“
Assembly overview - particulate filter
”
Chapter
“
Removing and installing engine mountings
”
Drive shafts; Assembly overview - drive shafts
Running gear, axles, steering
Rep. gr.
40
Drive shaft; Assembly overview - drive shaft
Noise insulation; Assembly overview - noise insulation
General body repairs, exterior
Rep. gr.
66
Noise insulation; Assembly overview - noise insulation
Component
Specified torque
Stud
15 Nm