Turbocharger With Attachments, Removing And Installing

Part I 

The following list pertains to Fig 1.

1. 40 Nm 
   • Coat threads with 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 together with turbocharger
   • Boost pressure regulation, checking, see BOOST PRESSURE SYSTEM, CHECKING 
5. Fuse 
6. Turbocharger 
   • Boost pressure regulation, checking, see BOOST PRESSURE SYSTEM, 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. Seal 
    • replace
    • Note installed position
11. 20 Nm 
12. Heat shield 
13. 10 Nm 
14. Banjo fitting, 30 Nm 
15. Oil supply line 
16. 30 Nm 
    • replace
    • Coat threads and bolt head contact surface with G 052 112 A3
17. Exhaust manifold 
18. Seal 
    • replace
    • Note installed position
19. 20 Nm 
20. Banjo fitting, 30 Nm 
21. 25 Nm 
    • replace
    • Coat threads with G 052 112 A3
22. B22 - Banjo fitting, 35 Nm 
23. Coolant return line 
24. 25 Nm 
25. Spacer sleeve 
26. Banjo fitting, 35 Nm 
27. 10 Nm 
28. Coolant supply line 
29. Banjo fitting, 35 Nm 
30. 30 Nm 
    • use only original bolts from parts catalog
31. Bracket 
    • Between turbocharger and cylinder block
32. 25 Nm 
33. Seal 
    • replace
34. Seal 
    • replace
35. 10 Nm 
36. Oil return line 
    • To oil pan
37. 10 Nm 
38. 10 Nm 

• Do not change orientation
• Must not be loosened
Fig 1: Exploded View Of Exhaust System And Turbocharger Assembly
Courtesy of VOLKSWAGEN OF AMERICA, INC.

Part II 

The following list pertains to Fig 2.

1. Deceleration shut-off valve 
   • Checking, see DECELERATION SHUT-OFF VALVE, CHECKING 
2. Connection hose 
   • To Recirculating valve for turbocharger -N249-*
3. Pressure regulator valve 
   • For crankcase ventilation
4. Connection hose 
   • from deceleration shut-off valve to upper air guide pipe
5. to crankcase breather valve 
6. From air filter 
7. upper air guide pipe 
   • note installation position of heat shield mat
   • Vehicles with engine code AWP, AWW with quick-release connection (with O-ring and retaining clip)
   • Vehicles with engine code AWD with screw-type clamps
8. Bracket 
9. 40 Nm 
10. 25 Nm 
11. to connection hose for lower connection sleeve/charge air cooler 
12. O-ring 
    • replace
    • only vehicles with engine code AWP, AWW
13. Retaining clip 
    • Check for secure fitting
    • only vehicles with engine code AWP, AWW
14. 10 Nm 
15. from turbocharger exhaust tube 
16. Connection hose 
17. Connection hose 
    • to vacuum diaphragm for boost pressure regulator valve
18. Retaining clip 
    • Check for secure fitting
19. O-ring 
    • replace
20. Intake hose 
    • to intake tube of turbocharger
21. Wastegate Bypass Regulator Valve - N75-* 

• Valve is activated (pulsed) by the Engine Control Module (ECM)
• Closed when no voltage present, limits charge pressure
• Checking, see WASTEGATE BYPASS REGULATOR VALVE, CHECKING 
Fig 2: Exploded View Of Turbocharger Attachments (Part II)
Courtesy of VOLKSWAGEN OF AMERICA, INC.