Removing and installing parts of the charge air system: VW (PG)

Checking charge air system for leaks => Page
21-10

Checking charge pressure => Page
21-15

Notes:

Ensure meticulous cleanliness is maintained when performing assembly work on charge air system of G-charger!
All hose connections are secured with clips.
Charge air system must be free of leaks.
If the G-charger has mechanical damage, it is possible that metal particles could get into the charge air system. To prevent subsequent damage, the following work must be carried out in addition to replacing the G-charger:

Clean air filter housing and replace air cleaner element.
Replace charge air cooler and silencer.
Clean air connecting hoses. If it is not possible to clean, replace parts.
Replace gaskets and seals.
Replace by-pass pipe.

Note:

The following work must be carried out only if a by-pass pipe without strainer was installed and metal particles have been detected in the removed by-pass pipe:

Clean inlet manifold.
Remove cylinder head => Page
15-1
Check cylinder head for damage and distortion.
Check pistons and cylinders for damage by metal particles.

Parts of charge air system engine side

45 Nm
Belt pulley
10 Nm
Air cleaner upper part
Connecting hose
O-ring
Renew

By-pass pipe
From by-pass valve housing to G charger

By-pass valve housing
Adjusting the by-pass flap

=> Repair group 24; Digifant injection and ignition system; Servicing injection part
4-Cyl. injection engine (G charger), Mechanics
Digifant injection and ignition system
Servicing injection part

From charge air cooler
=> Page
21-7
, Item
1

Silencer
Only remove/install complete
Must not touch reinforcement plate item
19

To charge air cooler
=> Page
21-9
, Item
16

25 Nm
Gasket
Renew

25 Nm
Remove and install with jointed spanner 3112

Support bracket

To cylinder block
=> Page
17-6
, Item
30

Bracket
Bracket
Before installing push bushes back
First tighten to cylinder block then to G-charger

Reinforcement plate
Installation position: straight end towards front

From cylinder head
=> Page
17-2
, Item
8

Seal
Renew

Banjo bolt, 15 Nm

G charger
Checking charge pressure
=> Page
21-15
Observe notes
=> Page
21-1

Bracket
For G-charger

Ribbed belt
Removing and installing
=> Page
13-16

Parts of charge air system body side

To by-pass flap housing
=> Page
21-4
, Item
9

Connecting hose
08.90 ▸

Connecting hose
▸ 07.90

Retaining clip
O-ring
Renew if damaged

Intake air temperature sender (G42)
With CO potentiometer (G74) and CO adjustment screw
Checking ▸07.92:

=> Repair Group 01; Electrical check; wiring and component check with test box V.A.G 1598
4-Cyl. injection engine (G charger), Mechanics
Electrical check
wiring and component check with test box V.A.G 1598

Checking 08.92 ▸:

=> Repair Group 01; Self diagnosis; Interrogating fault memory
4-Cyl. injection engine (G charger), Mechanics
Self diagnosis
Interrogating fault memory

Rubber grommet
10 Nm
Spacer bush
Connecting pipe
▸ 07.90

Connecting pipe
08.90 ▸

Connecting hose
Bracket
For charge air cooler

20 Nm
Charge air cooler
To remove, remove front bumper

=> General body repairs; Repair group 63; Servicing front bumper
General body repairs
Servicing front bumper

From G-charger
=> Page
21-4
, Item
11

Speed nut