Turbocharger And Exhaust Manifold With Attachments Overview

WARNING: This page is about a different car, the 2010 Volkswagen Jetta and 2009 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION:

Follow the safety precautions when working on the charge air system and turbocharger. Refer to SAFETY PRECAUTIONS .
Observe the rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Always follow these instructions before and during work.

NOTE:

Particulate filter with NOx reduction catalytic converter overview. Refer to one of the following:

Engine code CBEA, refer to PARTICULATE FILTER WITH NOX REDUCTION CATALYTIC CONVERTER OVERVIEW .

Engine code CJAA, refer to PARTICULATE FILTER WITH NOX REDUCTION CATALYTIC CONVERTER OVERVIEW .

Fig 1: Turbocharger And Exhaust Manifold With Attachments Overview

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Bolt
- 8 Nm
Warm Air Collector Plate
- To the warm air connecting hose -item 12 - in the AIR FILTER HOUSING OVERVIEW to the air filter.
Bolt
- 10 Nm
Oil Supply Line
- 22 Nm
- Do not change the angles of the oil supply line.
- Install without tension.
- From the oil filter bracket, see -item 6- in OIL FILTER BRACKET AND OIL COOLER OVERVIEW .
- Removing and installing, refer to OIL SUPPLY LINE TO TURBOCHARGER .
- Before installing, check the oil supply line for clear passage.
- Fill with engine oil before installing the turbocharger oil supply line to the connections.
Vacuum Hose
- Make sure the hose is seated correctly and is routed without kinks.
- To the wastegate bypass regulator valve -N75-.
- Vacuum hose connection diagram. Refer to VACUUM HOSE CONNECTION DIAGRAM .
Vacuum Diaphragm
- With the charge pressure actuator position sensor -G581-.
- Removing and installing, refer to VACUUM DIAPHRAGM WITH CHARGE PRESSURE ACTUATOR POSITION SENSOR -G581- .
Heat Shield
- Replace if damaged.
Heat Shield
Bracket
- For the wiring harness.
Seal
- Always replace.
Clamp
- 7 Nm
- Always replace.
- Note the installed position, refer to one of the following:
  Engine code CBEA, refer to PARTICULATE FILTER WITH NOX REDUCTION CATALYTIC CONVERTER OVERVIEW .
  
  Engine code CJAA, refer to PARTICULATE FILTER WITH NOX REDUCTION CATALYTIC CONVERTER OVERVIEW .
to the Particulate Filter
- Refer to one of the following:
  Engine code CBEA, refer to PARTICULATE FILTER WITH NOX REDUCTION CATALYTIC CONVERTER OVERVIEW .
  
  Engine code CJAA, refer to PARTICULATE FILTER WITH NOX REDUCTION CATALYTIC CONVERTER OVERVIEW .
Gasket
- Always replace.
- Note the installed position.
Turbocharger
- One unit with the exhaust manifold and vacuum diaphragm (cannot be replaced separately).
- Removing and installing, refer to TURBOCHARGER AND EXHAUST MANIFOLD .
Nut
- 23 Nm
- Always replace.
- Coat the studs for the exhaust manifold with hot bolt paste G 052 112 A3.
Heat Shield
Stud Bolt
- 20 Nm
Nut
- 23 Nm
- Installed on the stud bolt -item 17- on the turbocharger.
Nut
- 23 Nm
- To the exhaust manifold for the heat shield -item 16-.
Control Line
- 23 Nm
- Do not change the angles of the control line.
- Between the Exhaust Gas Recirculation (EGR) housing -item 16- in the EXHAUST GAS RECIRCULATION SYSTEM COMPONENT OVERVIEW and the exhaust pressure sensor 2 -G451-, refer to one of the following:
  Engine code CBEA, see -item 1- in the PARTICULATE FILTER WITH NOX REDUCTION CATALYTIC CONVERTER OVERVIEW .
  
  Engine code CJAA, see -item 1- in the PARTICULATE FILTER WITH NOX REDUCTION CATALYTIC CONVERTER OVERVIEW .
- To loosen at the housing -item 16- in the EXHAUST GAS RECIRCULATION SYSTEM COMPONENT OVERVIEW remove the EGR filter -item 9- in the EXHAUST GAS RECIRCULATION SYSTEM COMPONENT OVERVIEW .
- Install without tension.
Filter
- For the EGR system.
- See -item 9- in the EXHAUST GAS RECIRCULATION SYSTEM COMPONENT OVERVIEW .
Brace
- For the turbocharger.
Seal
- Always replace.
Banjo Bolt
- 60 Nm
- Always replace.
O-ring
- Always replace.
Oil Return Line
- Install without tension.
Bolt
- 15 Nm
Damper
- To the hot side upper charge air hose -item 13- in the CHARGE AIR COOLER COMPONENT OVERVIEW .
Connecting Pipe
CAUTION:
Make sure the connecting pipe coupling element does not bend or stretch. Cracks could develop.
- Between the exhaust manifold and intake manifold, see -item 5- in the INTAKE MANIFOLD AND ATTACHMENTS OVERVIEW .
- Always replace.
- Install without tension.
Nut
- 20 Nm
- Coat the studs for the exhaust manifold with hot bolt paste G 052 112 A3.
Connecting Pipe
- From the EGR housing -item 2- in the EXHAUST GAS RECIRCULATION SYSTEM COMPONENT OVERVIEW .
- To remove and install, also loosen the connecting piece -item 33- on the turbocharger.
Seal
- Replace if damaged.
Connecting Piece
O-ring
- Replace if damaged.
Intake Scoop
- Ensure the scoop is seated securely.
- Clean if there are contaminants
- To the intake tube -item 1- in the AIR FILTER HOUSING OVERVIEW from the air filter housing.
- With the Positive Crankcase Ventilation (PCV) heating element.
  Removing:
  
  -- Disconnect the crankcase ventilation hose from the intake scoop.
  
  NOTE:
  The crankcase ventilation hose is destroyed when it is removed.
  
  -- Remove the bolt -item 36-.
  
  -- Rotate the intake scoop clockwise and remove it from the connecting piece -item 33-.
  
  Installing:
  
  -- Clean the intake scoop. It must be free of oil and grease.
  
  -- Slide the intake scoop onto the connecting piece -item 33- and rotate it counterclockwise until it engages on the connecting piece.
  
  -- Tighten the bolt -item 36-.
  
  -- Install a new crankcase ventilation hose.
Bolt
- 8 Nm
Exhaust Gas Temperature Sensor 1 -G235-
- 45 Nm
- Note the installed position, refer to Fig 2.
- Coat only the threads with hot bolt paste G 052 112 A3.

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 EGT sensor 1 with an angled shaft.