Turbocharger Overview

WARNING: This page is about a different car, the 2015 Volkswagen Beetle, 2014 Volkswagen Beetle, and 2013 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

Various hose connections are secured.

Charge air system must be properly sealed.

Replace the self-locking nuts.

Before screwing on oil supply line, fill turbocharger with engine oil at filler tube.

After installing turbocharger, let engine idle for approximately one minute to ensure adequate oil supply to the turbocharger.

NOTE:

Refer to PARTICULATE FILTER OVERVIEW .

Fig 1: Identifying Turbocharger And Exhaust Manifold With Attachments Overview

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Bolt
- 8 Nm
Warm Air Collector Plate
Bolt
- 10 Nm
Oil Supply Line
- Do not change the angles of the oil supply line
- Install without tension
- Before installing, check oil supply line for clear passage
- Fill with engine oil before installing the turbocharger oil supply line on the connections
- 22 Nm
Vacuum Hose
- Make sure it is seated correctly and is routed without kinks
- To wastegate bypass regulator valve -N75-
- Connection diagram for vacuum hoses. Refer to VACUUM SYSTEM CONNECTION DIAGRAM .
Vacuum Diaphragm
- With the charge pressure actuator position sensor -G581-
- Removing and installing. Refer to TURBOCHARGER VACUUM DIAPHRAGM, REPLACING .
- Unit with turbocharger and exhaust manifold (cannot be replaced separately)
Heat Shield
- Replace if damaged
Heat Shield
Bracket
- For wiring harness
Seal
- Replace after removing
Securing Clamp
- Installation position. Refer to PARTICULATE FILTER OVERVIEW .
- Replace after removing
- 7 Nm
To the Particulate Filter
- PARTICULATE FILTER OVERVIEW
Seal
- Pay attention to the installed position.
- Replace after removing
Turbocharger
- Unit with exhaust manifold and pressure cell (cannot be replaced separately)
- For removing and installing, refer to TURBOCHARGER .
Nut
- Coat stud bolts on exhaust manifold with Hot Bolt Paste G 052 112 A3.
- Replace after removing
- 23 Nm
Heat Shield
Hex Stud
- 20 Nm
Nut
- Installed on the stud bolt TURBOCHARGER OVERVIEW => List Item:Hex Stud on the turbocharger
- 23 Nm
Nut
- Secure on the exhaust manifold with the heat shield TURBOCHARGER OVERVIEW => List Item:Heat Shield
- 23 Nm
Control Wire
- Do not change the angles of the control line
- To loosen at the housing EXHAUST GAS RECIRCULATION OVERVIEW => List Item:Housing remove the exhaust gas recirculation filter EXHAUST GAS RECIRCULATION OVERVIEW => List Item:Filter
- Install without tension
- 23 Nm
Filter
- For the exhaust gas recirculation
- Refer to EXHAUST GAS RECIRCULATION OVERVIEW => List Item:Filter .
Support
- For the turbocharger
Seal
- Replace
Banjo Bolt
- Replace after removing
- 60 Nm
O-Ring
- Replace
Oil Return Pipe
- Install without tension
Bolt
- 15 Nm
Pulsation Damper
- To the >>hot<< side connecting hose, upper CHARGE AIR SYSTEM OVERVIEW => List Item:Connecting Hose
Connecting Pipe
CAUTION:
Make sure the connecting pipe decoupling element does not bend or stretch. Cracks could develop.
- Between the exhaust manifold and intake manifold
- Install without tension
- Replace the seal after removal.
Nut
- Coat stud bolts on exhaust manifold with Hot Bolt Paste G 052 112 A3.
- 20 Nm
Connecting Pipe
- From the exhaust gas recirculation housing EXHAUST GAS RECIRCULATION OVERVIEW => List Item:Connecting Pipe
- To remove and installing, also loosen the connections TURBOCHARGER OVERVIEW => List Item:Connecting Piece on the turbocharger
Seal
- Replace if damaged
Connecting Piece
O-Ring
- Replace if damaged
Intake Scoop
- Make sure it is secure
- Clean if there are contaminants
- From the intake hose on the air filter
- With Positive Crankcase Ventilation (PCV) Heating Element --
  Removing:
  
  -- Disconnect the crankcase ventilation hose at the intake scoop.
  
  NOTE:
  The crankcase ventilation hose is destroyed when it is removed.
  
  -- Remove the bolt TURBOCHARGER OVERVIEW => List Item:Bolt.
  
  -- Rotate the intake scoop clockwise and remove it from the connections TURBOCHARGER OVERVIEW => List Item:Connecting Piece.
  
  Installing:
  
  -- The intake scoop must be free oil and grease.
  
  -- Slide the intake scoop onto the connections TURBOCHARGER OVERVIEW => List Item:Connecting Piece and rotate it counterclockwise until it engages on the connections.
  
  -- Tighten the bolt TURBOCHARGER OVERVIEW => List Item:Bolt.
  
  -- Install a new crankcase ventilation hose.
Bolt
- 8 Nm
Exhaust Gas Temperature Sensor 1 -G235-
- Removing and Installing tool set SW 17 T10395
- Installation position Fig 2.
- Coat only the thread with Hot Bolt Paste G 052 112 A3
- 45 Nm

Fig 2: Installed Position, Exhaust Gas Temperature (EGT) Sensor 1 with Angled Shaft

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

Always adhere to dimension -a- 3 to 5 mm to the threaded connection on the turbocharger support when installing the exhaust gas temperature sensor with an angled shaft.