Removing and installing oil return line for turbocharger: VW (CAYC, CFFB)

🧭 Before you start

Fits: platform code A32

• Renewed: gaskets

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• When installing the exhaust temperature sender with angled cable guide, the measurement (a) of 3 … 5 mm from the turbocharger support threaded connection must be adhered to.

🔧 Engine codes this applies to

📋 Procedure

1. Remove engine cover panel .
2. Remove noise insulation General body repairs, exterior66Noise insulation; Assembly overview - noise insulation.
3. Remove heat shield for right drive shaft.
4. ⚠ Avoid damage to the flexible joint:Do not bend decoupling element more than 10°.Install decoupling element so that it is not under tension.Take care not to damage wire mesh on decoupling element.The decoupling element must be secured with transportation lock T10404 to stop overstretching. — Remove particulate filter from upper bracket and loosen bracket on cylinder head .
5. Remove securing clamp (2) between particulate filter and turbocharger.

6. Disconnect connector (2) from pressure differential sender G505.
7. Unscrew bolts (3) and (4).
8. Unscrew securing nuts (2) from lower bracket of particulate filter.
9. Place particulate filter aside.
10. Remove securing bolt on the retaining clamp (arrow) for the oil return line on the turbocharger support.
11. Remove only right connecting pipe (A) to exhaust gas recirculation cooler, as illustrated.
12. Unscrew upper bolt (arrow) from support on turbocharger.
13. Release oil supply line banjo bolt at crankcase.
14. Release banjo bolt for turbocharger support at crankcase.
15. Release combination flange (oil supply/return) at turbocharger.
16. Unscrew released connections.
17. Remove combination flange (oil supply and return) together with turbocharger support. [Note: Renew gaskets, seals, O-rings and self-locking nuts Electronic Parts Catalogue.Renew particulate filter clip Electronic Parts Catalogue.If particulate filter or pressure differential sender G505 is exchanged, pressure differential sender G505 must be adapted using vehicle diagnosis tester: Guided functions; Adapting pressure differential sender G505.After working on the exhaust system, ensure that the system is not under stress and that there is sufficient clearance to the bodywork. If necessary, loosen double clamp and align silencer and exhaust pipe so that sufficient clearance is maintained to the bodywork and the support rings are evenly loaded.]
18. Place combined flange (oil supply and return line) on turbocharger and turbocharger support on turbocharger and crankcase.
19. Fit oil supply line in position on crankcase.
20. First bolt turbocharger support to crankcase and turbocharger by hand.
21. Then tighten turbocharger support bolts on crankcase and turbocharger in stages and alternately up to the specified torque.
22. Next tighten the bolts on the combined flange and the banjo bolt for the oil supply line on the crankcase.
23. Finally tighten the bolt on the oil supply line/turbocharger support clamp.
24. Further assembly is carried out in the reverse order of removal. [Note: When installing the exhaust temperature sender with angled cable guide, the measurement (a) of 3 … 5 mm from the turbocharger support threaded connection must be adhered to.]

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