Part I

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Fig 1: Turbocharger With Attachments, Assembly Overview - Part I

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - 40 Nm

Coat threads with hot bolt paste G 052 112 A3

2 - Seal

Replace

3 - 10 Nm

Must not be loosened

4 - Vacuum diaphragm

For boost pressure regulator valve
Can only be replaced as together with turbocharger
Charge pressure regulation, checking refer to Boost pressure regulation, checking

5 - Fuse

6 - Turbocharger

Charge pressure regulation, checking refer to Boost pressure regulation, checking
The boost pressure regulator valve and vacuum diaphragm for boost pressure regulator valve are part of the exhaust turbocharger and cannot be replaced individually.
Before connecting oil supply line, fill turbocharger with oil at filler tube
After installing turbocharger, let engine idle for approx. 1 minute without increasing engine speed. This ensures adequate oil supply to the turbocharger.

7 - O-ring

Replace

8 - 10 Nm

9 - Intake manifold

10 - Gasket

Replace
Note installation position

11 - 20 Nm

12 - Heat shield

13 - 10 Nm

14 - Banjo bolt, 30 Nm

15 - Oil supply line

16 - 30 Nm

Replace
Coat threads and bolt head contact surfaces with Hot Bolt Paste G 052 112 A3 (Part numbers are for reference only. Always check with your Parts Department for the latest part number information).

17 - Exhaust manifold

18 - Gasket

Replace
Note installation position

19 - 20 Nm

20 - Banjo bolt, 30 Nm

21 - 25 Nm

Replace
Coat threads with hot bolt paste G 052 112 A3 (Part numbers are for reference only. Always check with your Parts Department for the latest part number information).

22 - Banjo bolt, 35 Nm

23 - Coolant return line

24 - 25 Nm

25 - Spacer sleeve

26 - Banjo bolt, 35 Nm

27 - 10 Nm

28 - Coolant supply line

29 - Banjo bolt, 35 Nm

30 - 30 Nm

Only use original bolt from parts catalog

31 - Bracket

Between turbocharger and cylinder block

32 - 25 Nm

33 - Gasket

Replace

34 - Gasket

Replace

35 - 10 Nm

36 - Oil return line

To oil pan

37 - 10 Nm

38 - 10 Nm

Do not change adjustment
Must not be loosened