Removing and installing turbocharger, Passat: VW 1.6 TDI (CAYC)

🧭 Before you start

Fits: VW Passat B6 (3C, 2005–2010), VW Passat B7 saloon (362, 2010–2014), VW Passat B7 Variant (365, 2010–2014)

• Renewed: turbocharger, seals

Don't miss

• Disregard (item 3).

🔧 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.Check complete charged air routing and charge air cooler for foreign objects.If foreign objects are found in the charge air system, the charged air routing must be cleaned and the charge air cooler must be renewed, if necessary. — Remove engine cover .
2. Remove air filter housing with air mass meter and connecting pipe .
3. With ignition switched off, disconnect earth strap from battery. Electrical system27Battery; Disconnecting and connecting battery
4. Remove battery and battery tray Electrical system27Battery; Removing and installing battery.
5. Remove crankcase breather hose (1) from cylinder head cover; press release buttons for this.

6. Free vacuum hoses (arrows).
7. Unscrew bolt (2), swing intake hose with intake connection to rear and pull off of turbocharger.
8. Detach vacuum line (arrow) from brake booster and vacuum pump.
9. Remove heat shield sleeve from position sender for charge pressure positioner G581.
10. Disconnect electrical connector (1) at position sender for charge pressure positioner G581.
11. Pull vacuum hose (2) from turbocharger vacuum unit.
12. Separate vacuum hose (3).
13. Disconnect connectors (1...4).
14. Remove bolt (arrow).
15. Place bracket plate with solenoid to one side.
16. Unscrew bolt (1).
17. Unscrew securing clamp (2) between particulate filter and turbocharger.
18. Remove bolts (arrows).
19. Take off pulsation damper (2).
20. Detach vacuum line (2).
21. Lay vacuum lines to side.
22. Remove bolt (arrow).
23. Separate electrical connector (1) on oil pressure switch F1.
24. Remove suspension eye and oil pressure switch F1.
25. Unscrew bolts and remove pipes (A) for exhaust gas recirculation.
26. Loosen coolant lines Heating, air conditioning87Coolant circuit.
27. Unscrew securing nuts (2) for particulate filter bracket on crankcase.
28. Unscrew bolts (1, 2), and banjo bolts (4, 5) and remove turbocharger support with oil supply line. [Note: Disregard (item 3).]
29. Disconnect connector on oil level and oil temperature sender G266.
30. Remove bolts (1…2...3).
31. Remove pendulum support.
32. Using tensioning strap T00038 as (shown), pull engine towards assembly mountings.
33. Unscrew bolts (arrows) and remove heat shield.
34. Unscrew nuts (arrows) and pull turbocharger with exhaust manifold off cylinder head.
35. Carefully remove turbocharger from above in direction of gearbox.
36. ⚠ Before installing, check whether flexible joint of oil return line is bent and thus stretched. If this is the case, micro cracks can have formed and may cause leakage. If necessary, renew oil return line of turbocharger before installing. — Install in reverse order. In the process, note the following: [Note: Renew seals, gaskets, O-rings and self-locking nuts.Fill turbocharger with engine oil at connection for oil supply line.Hose connections and air intake pipes and hoses must be free of oil and grease before installation.Secure all hose connections with the correct type of hose clips (same as original equipment) Electronic Parts Catalogue.After installing turbocharger, run engine for about 1 minute at idling speed to ensure that oil is supplied to turbocharger.Reinstall heat insulation sleeves in the original positions when installing.] [Note: When installing the exhaust temperature sender with angled cable guide, adhere to dimension (a) of 3 … 5 mm from the turbocharger support threaded connection.]

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