Removing and installing turbocharger with attached parts — VW

AHD ANJ APA BBE BBF
Observe rules for cleanliness => page
21-14
.

Engine codes AHD, APA, BBE, BBF => page
21-2

Engine code ANJ => page
21-7

Removing and installing parts of intercooler
=> page
21-11
.

Note:

All hose connections are secured with clips.
Charge air system must be leak-free.
Renew all self-locking nuts.
The assembly tool VAS 5024 or the pliers V.A.G 1921 is/are recommended for mounting the spring clips.

Engine codes AHD, APA, BBE, BBF

Connecting pipe
To EGR valve
=> page
26-12
, item
3

25 Nm
Heat shield
For intake manifold

Seal
Renew
Ensure proper installation position

Exhaust manifold
To vacuum hose
=> page
21-5
, item
21

Vacuum hose
blue

Oil supply line
Fill turbocharger with engine oil at fitting of oil supply line before installing
From oil filter holder
=> page
17-7
, item
6

To vacuum hose
=> page
21-4
, item
18

Vacuum hose
Yellow

Sealing ring
Renew

Banjo bolt, 30 Nm
Connecting pipe
Between turbocharger and connecting hose of air volume sensor
Secured on turbocharger and oil filter holder

10 Nm
Bracket
For EGR valve (N18) and solenoid valve for boost pressure control (N75)

Solenoid valve for boost pressure control (N75)
Check boost pressure control
=> page
20-21
Check actuation

=> Repair group 01; Self-Diagnosis; Final control diagnosis
5-Cyl. Diesel Engine, Mechanics
Self-Diagnosis
Final control diagnosis

Vacuum hose
Yellow

To control line
=> page
21-5
, item
25

Connecting plug
2-pin
For solenoid valve for boost pressure control (N75)

Vacuum hose
blue

Seal
Renew

Banjo bolt, 15 Nm
O-ring
Renew if damaged

Control line
Red

Wastegate
Part of turbocharger and cannot be renewed
Check boost pressure control
=> page
21-21

Oil return line
To cylinder block

30 Nm

Turbocharger
Removing and installing
=> page
21-15
Check boost pressure control
=> page
21-21

Front exhaust pipe
With catalyst

Cap nut, 25 Nm
Charge air hose
To charge air pipe
=> page
21-11
, item
4

60 Nm
Renew
Coat thread and head contact surface with lubricating grease G 000 500

Engine codeþöï

Clamp on exhaust manifold
Connecting pipe
Clamp on EGR valve
To EGR valve
=> page
26-12
, item
3

Seal
Renew
Ensure proper installation position

Heat shield
For intake manifold

Washer
25 Nm

Oil supply line
Fill turbocharger with engine oil at fitting of oil supply line before installing

Banjo bolt, 30 Nm
Sealing ring
Renew

To charge air pipe
=> page
21-11
, item
4

Charge air hose
Connecting pipe
Between turbocharger and connecting hose of air volume sensor
Secured on turbocharger and oil filter holder

10 Nm

Seal
Renew

30 Nm
Oil return line
To cylinder block

25 Nm
Control line
Connection diagram for vacuum hoses => page
26-16

Wastegate
Support
55 Nm
Seal
Renew

25 Nm
Renew

Front exhaust pipe
With catalyst

Turbocharger
Removing and installing
=> page
21-15
Check boost pressure control
=> page
21-21

Cap nut, 25 Nm
Exhaust manifold
25 Nm
Renew

25 Nm
Renew
Coat thread and head contact surface with lubricating grease G 000 500