Removing and installing turbocharger, engine code CJAA — VW

🧭 Before you start

Fits: VW Golf VI (5K, 2008–2013); platform code 521

• Renewed: turbocharger, charge air cooler

Don't miss

• Exhaust gas temperature sender 1G235 conceals the upper bolt of the exhaust gas turbocharger support. It must not be bent. It must therefore be removed. — Remove exhaust gas temperature sender 1G235.

🔧 Engine codes this applies to

📋 Procedure

1. ⚠ When a mechanical fault is found on the turbocharger, e.g. a destroyed compressor impeller, it is not only sufficient to renew the turbocharger. To prevent this from causing further damage, perform the following repairs:Check air filter housing, air filter element and intake hoses for soiling , Assembly overview - air filter.If foreign objects are found in the charge air system:Check complete charged air routing and charge air cooler for foreign objects , Assembly overview - parts of charge air cooling.Renew connecting pipe between exhaust manifold and intake manifold .Clean complete charged air routing and if necessary, renew charge air cooler.Check housing and cooler for exhaust gas recirculation for foreign objects , Assembly overview - parts of exhaust gas recirculation system.Check oil lines on turbocharger for soiling and foreign objects , Assembly overview - turbocharger with exhaust manifold and attachments. — Remove particulate filter with NOx storage catalytic converter .
2. ⚠ Exhaust gas temperature sender 1G235 conceals the upper bolt of the exhaust gas turbocharger support. It must not be bent. It must therefore be removed. — Remove exhaust gas temperature sender 1G235.
3. Remove control line between exhaust gas recirculation housing and exhaust gas pressure sensor 2G451.
4. Remove housing with cooler for exhaust gas recirculation , Assembly overview - parts of exhaust gas recirculation system.
5. Pull off connector for position sender for charge pressure positioner G581(2) at vacuum unit.

6. Pull vacuum hose (3) off turbocharger vacuum unit.
7. Disconnect »black« connector for exhaust temperature sender 1G235(2) at plenum chamber bulkhead.
8. Guide lines out of retainers on plenum chamber bulkhead and on turbocharger.
9. Remove connecting pipe .
10. Remove oil supply line .
11. Remove banjo bolt of turbocharger support.
12. Unscrew hexagon drive stud from support on turbocharger.
13. Turn lower part of support 90° and pull support downwards off upper part.
14. Remove heat shield from exhaust manifold.
15. Unscrew securing nuts for exhaust manifold.
16. Remove turbocharger with exhaust manifold from cylinder head, turning so that intake side points down. Remove turbocharger and exhaust manifold downwards.

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