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Home >> Volkswagen >> 2003 >> GTI Base, Automatic >> Repair and Diagnosis >> External Pages >> Different car >> Section 166 (1.9L - Turbocharger, G-Charger - Engine Code(S): BKC, BLS, BRM & BXE (A5 Platform)) >> 21 Turbocharger, G-Charger >> Description And Operation >> Turbocharger Assembly Overview

Turbocharger Assembly Overview

WARNING: This page is about a different car, the 2006 Volkswagen Jetta and 2005 Volkswagen Jetta. 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 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 1 minute to ensure adequate oil supply to the turbocharger.

Fig 1: Identifying Turbocharger Assembly Overview
GWWM21-0164Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
  1. Union nut, 22 Nm 
  2. 10 Nm 
  3. Oil supply line 
    • Before installing, check oil supply line for clear passage
    • Before installing, fill turbocharger with engine oil at connection of oil supply line
    • Removing and installing OIL SUPPLY LINE .
  4. Connection, 30 Nm 
    • Replace
    • Coat threads and bolt head contact surface with hot bolt paste G 052 112 A3
  5. Seal 
    • Replace
  6. Connector 
    • For Turbocharger (TC) vane position sensor -G500-
  7. Heat shield 
    • With bracket for oxygen sensor wiring harness
  8. Gasket 
    • Replace
    • Note installation position
  9. Clamp, 7 Nm 
    • Replace
  10. Front exhaust pipe 
  11. 25 Nm 
  12. 25 Nm 
    • Replace
    • Coat stud bolts on cylinder head with hot bolt paste G 052 112 A3
  13. Connecting pipe 
    • To cooler for exhaust gas recirculation
  14. Gasket 
    • Replace
  15. Gasket 
    • Replace
    • Note installation position
  16. Turbocharger 
    • Only replace complete with exhaust manifold and Turbocharger (TC) vane position sensor -G500-
    • Removing and installing TURBOCHARGER .
  17. Banjo bolt, 60 Nm 
    • Replace
  18. O-ring 
    • Replace
    • Before installing, thinly coat with clean engine oil
  19. Oil return line 
    • To cylinder block
    • Complete installing and removing
  20. O-ring 
    • Remove and replace only if there are leaks in the oil return line
    • Before installing, thinly coat with clean engine oil
  21. Air duct 
    • To air filter
    • For warm air intake
    • Only for cold climate equipment
    • Installed on the shield, refer to "Heat shield" in item:  22
  22. Heat shield 
  23. Connecting pipe 
  24. Spring-type clip 
  25. Connecting hose 
  26. 8 Nm 
    • Replace
  27. Vacuum hose 
  28. 4 Nm 
  29. O-ring 
    • Replace
  30. Turbocharger (TC) vane position sensor -G500- 
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