Removing and installing turbocharger with exhaust manifold (engine codes CBEA, CJAA) — 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

📐 33 workshop diagrams for CBDA

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 , 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.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. ⚠ 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.
3. Remove control line between exhaust gas recirculation housing and exhaust gas pressure sensor 1G450.
4. Remove housing with cooler for exhaust gas recirculation , Assembly overview - parts of exhaust gas recirculation.
5. Pull connector off position sender for charge pressure positioner G581(2) at turbocharger 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, turn it so that intake side faces downwards and remove turbocharger with exhaust manifold downwards.

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