Removing and installing turbocharger with exhaust manifold (engine codes CBDA, CBDB, CEGA) — VW

🧭 Before you start

Fits: VW Jetta VI (16, 2010–2018), VW Golf V / Jetta (1K, 2003–2009); platform code AJ5

• Renewed: turbocharger, charge air cooler

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• The exhaust gas temperature sender 1G235 covers the upper threaded connection of the turbocharger support and 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.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.Check oil lines on turbocharger for soiling and foreign objects , Assembly overview - turbocharger with exhaust manifold and attachments. — Remove intake pipe (1) and disconnect connector of position sender for charge pressure positioner G581(2) from turbocharger.
2. Pull vacuum line (3) off turbocharger.
3. Disconnect connector for exhaust gas temperature sender 1G235(1) from plenum chamber bulkhead and guide wire out of retainers.
4. Unscrew oil supply line (arrow) from turbocharger.
5. Remove securing bolt (1) from charge air pipe, loosen clamp (2) and pull off connecting hose at turbocharger as far as it will go.

6. Remove particulate filter .
7. Remove connecting pipe (A) to exhaust gas recirculation cooler.
8. ⚠ The exhaust gas temperature sender 1G235 covers the upper threaded connection of the turbocharger support and must not be bent. It must therefore be removed. — Remove exhaust gas temperature sender 1G235.
9. Pull right axle shaft off bevel box Running gear, axles, steering40.
10. Remove banjo bolt of turbocharger support.
11. Unscrew upper bolt (arrow) from support on turbocharger.
12. Turn lower part of support 90° and pull support downwards off upper part.
13. Remove heat shield from exhaust manifold.
14. Unscrew securing nuts for exhaust manifold.
15. Take off turbocharger, turn it so that intake side faces downwards and remove turbocharger downwards.
16. ⚠ Before installing, check whether decoupling element 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:

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