Turbocharger With Exhaust Manifold And Attachments Overview

WARNING: This page is about a different car, the 2014 Volkswagen Jetta, 2013 Volkswagen Jetta, 2012 Volkswagen Jetta, and 2011 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: Identifying 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, refer to -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, refer to -item 6- in the 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.
- Vacuum hose connection diagram, refer to VACUUM HOSE CONNECTION DIAGRAM .
Vacuum Diaphragm
- With the charge pressure actuator position sensor.
- Removing and installing, refer to Charge Pressure Actuator Position Sensor -G581- WITH THE VACUUM DIAPHRAGM .
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 WITH 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, refer to -item 16- in the EXHAUST GAS RECIRCULATION SYSTEM COMPONENT OVERVIEW and the Exhaust Pressure Sensor 1 -G450-, refer to one of the following:
  Engine code CBEA, refer to -item 1- in the PARTICULATE FILTER WITH NOX REDUCTION CATALYTIC CONVERTER OVERVIEW .
  
  Engine code CJAA, refer to -item 1- in the PARTICULATE FILTER WITH NOX REDUCTION CATALYTIC CONVERTER OVERVIEW .
- To loosen at the housing, refer to -item 16- in the EXHAUST GAS RECIRCULATION SYSTEM COMPONENT OVERVIEW .
- To remove the EGR filter, refer to -item 9- in the EXHAUST GAS RECIRCULATION SYSTEM COMPONENT OVERVIEW
- Install without tension.
Filter
- For the EGR system.
- Refer to -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, refer to -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, refer to -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, refer to -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, refer to -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
- Remove and install using Tool Set 17 mm T10395
- 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- of 3 to 5 mm to the threaded connection on the turbocharger support when installing the Exhaust Gas Temperature Sensor 1 -G235- with an angled shaft.