Removing and installing turbocharger, Polo: VW 1.6 TDI (CAYA, CAYB, CAYC)

🧭 Before you start

Disconnect the battery earth and remove the engine cover, positioner connector, air filter housing and plenum bulkhead. Loosen and support the particulate filter after fitting the transport lock to the front pipe decoupling element. Remove the oil supply and return lines, vacuum line, pulsation damper, EGR pipes and heat shield, then unbolt the manifold and lift the turbocharger out towards the gearbox. Refit in reverse, observing the particulate filter installation sequence.

Fits: VW Polo 6R (2009–2014)

• Renewed: turbocharger

Don't miss

• After a mechanical turbo failure, check the air filter, intake and charge air routing for debris; clean or renew the intercooler.
• Fit the transport lock on the front pipe decoupling element before moving the particulate filter.
• Renew the oil return line if its flexible joint is bent or stretched.
• Set the angled exhaust temperature sender cable 3 … 5 mm from the turbo support connection.

Written for this job from the workshop steps below · TorqFix editorial.

🔧 Engine codes this applies to

📐 66 workshop diagrams for CAYA

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 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. — With ignition switched off, disconnect earth strap from battery. Electrical system27Battery; Disconnecting and connecting battery
2. Remove engine cover .
3. Pull connector (1) off position sender for charge pressure positioner G581 on turbocharger.
4. Remove air filter housing with air mass meter and intake hose .
5. Remove plenum chamber bulkhead General body repairs, exterior50Plenum chamber bulkhead; Assembly overview - bulkhead.

6. Loosen particulate filter. To do this, unscrew bolt (1).
7. Loosen bolt (2) and remove clamp.
8. Disconnect electrical connector (3).
9. Unscrew bolt (2), remove pressure differential senderG 505, free hoses (1).
10. On decoupling element in front exhaust pipe, fasten the transport lock T10403(arrow).
11. Unscrew bolts (1) and nuts (2), remove bracket for particulate filter.
12. Pull particulate filter from mountings (arrows).
13. Loosen securing bolts (arrows) of clamping sleeve, then push down backwards from front exhaust pipe.
14. Move particulate filter to side and fix using suitable means.
15. Remove oil supply line together with oil return line (turbocharger support) .
16. Pull vacuum line (3) off turbocharger.
17. Remove pulsations damper with connecting hose to charge air pipe.
18. Remove bolts (arrows).
19. Take off pulsation damper (2).
20. Unscrew bolts and remove pipes (A) for exhaust gas recirculation.
21. Unscrew bolts (arrows) and remove heat shield.
22. Unscrew nuts (arrows) and pull turbocharger with exhaust manifold off cylinder head.
23. Carefully remove turbocharger from above in direction of gearbox.
24. ⚠ 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: When installing the exhaust temperature sender with angled cable guide, adhere to dimension (a) of 3 … 5 mm from the turbocharger support threaded connection.]
25. Observe sequence when installing particulate filter:

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