Volkswagen Golf Variant / Jetta. Manual - part 424

 

  Index      Volkswagen     Volkswagen Golf Variant (2007), Jetta (2005) - service repair manual

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  422  423  424  425   ..

 

 

Volkswagen Golf Variant / Jetta. Manual - part 424

 

 

perature Sensor 1 - G235- -2- at the plenum chamber bulk‐

head.

– Guide the wire out of the retainer on the plenum chamber

bulkhead and on the turbocharger.

– Remove the connecting pipe -item 31- 

⇒ Item 31 (page 273)

 .

– Remove the oil supply line. Refer to

⇒ “4.3 Oil Supply Line to Turbocharger, Removing and Instal‐

ling”, page 182

 .

– Remove the banjo bolt -item 24- 

⇒ Item 24 (page 273)

 from

the turbocharger support.

– Remove the hex bolt -item 17- 

⇒ Item 17 (page 272)

 from the

turbocharger support.

– Rotate the lower section of the support 90° and remove the

support downward from the upper section.

– Remove the heat shield -item 16- 

⇒ Item 16 (page 272)

 on the

exhaust manifold.

– Remove the exhaust manifold nuts -item 15-

⇒ Item 15 (page 272)

 .

– Remove the turbocharger with the exhaust manifold from the

cylinder head. Turn it so that the intake side points downward

and remove the turbocharger with the exhaust manifold down‐

ward.

Installing

Caution

Before installing, check if the oil return pipe decoupling element

is bent or stretched. If this is the case, there could be micro

tears which could result in leaks. If necessary, replace the oil

return pipe before installing the turbocharger.

Install in reverse order of removal. Note the following:
• Always replace the self-locking nuts, seals, gaskets and

clamps.

• Insert the turbocharger with the pressure side upward.
• Position the charge air pipe connecting hose before securing

the turbocharger.

• Pay attention to the installation position of the Exhaust Gas

Temperature Sensor 1 - G235- . Refer to

⇒ Fig. ““Installed Position, Exhaust Gas Temperature Sensor

with Angled Shaft”“ , page 274

 :

• Replace the banjo bolt with the turbocharger support gaskets

as well as the oil return pipe O-rings.

• Do not stretch the oil return pipe decoupling element when

installing the turbocharger support.

3.3

Turbocharger with Exhaust Manifold,

Removing and Installing, Engine Codes

CBDA, CBDB, CEGA

Special tools and workshop equipment required
♦ Torque Wrench 1331 5-50Nm - VAG1331-

3. Turbocharger    

279

♦ Follow the safety precautions when working on the charge

air system and turbocharger. Refer to

⇒ “1 Safety Precautions when Working on Charge Air

System And Turbocharger”, page 268

 .

♦ Pay attention to the guidelines for clean working condi‐

tions. Refer to

⇒ “2 Guidelines for Clean Working Conditions”,

page 269

 .

Always pay attention to these instructions before and during

work.

Removing

Caution

If mechanical damage is found on exhaust turbocharger, for

example a destroyed compression wheel, it is not enough to

just replace the turbocharger. Perform the following steps to

prevent subsequent damage.
Check the air filter housing, the air filter insert and the intake

hoses 

for 

contamination. 

Refer 

to

⇒ “3.14 Overview - Air Filter”, page 335

 , Overview - Air Filter

If foreign objects are found in the charge air system:

♦ Check the entire charge air circuit and the charge air cool‐

er for foreign objects. Refer to

⇒ “4.2 Overview - Charge Air Cooler Components”,

page 290

 , Overview - Charge Air Cooling System Com‐

ponents

♦ Clean the entire charge air circuit and replace the charge

air cooler if necessary.

♦ Check the housing and the exhaust gas recirculation cool‐

er for foreign objects. Refer to

⇒ “4.1 Overview - Exhaust Gas Recirculation System

Components”, page 403

 , Overview - Exhaust Gas Re‐

circulation Components

♦ Check the oil lines on the turbocharger for contamination

and foreign objects. Refer to

⇒ “3.1 Overview - Turbocharger with Exhaust Manifold

and Attachments”, page 270

 , Overview - Turbocharger

with Exhaust Manifold and Attachments

– Remove the intake line -1- and disconnect from the Charge

Air Pressure Actuator Position Sensor - G581- -2- on the tur‐

bocharger.

– Disconnect the vacuum line -3- on the turbocharger.

280

sor 1 - G235- -1- on the plenum chamber bulkhead and guide

the wire out of the retainers.

– Remove the oil supply line on the turbocharger -arrow-.

– Remove the charge air pipe screw -1-, loosen the clamp -2-

and pull off the connecting hose from the turbocharger as far

as possible.

– Remove the particulate filter. Refer to

⇒ “2 Exhaust System, Engine Codes CBDA, CBDB and CE‐

GA”, page 388

 .

– Remove the connecting pipe -A- to the EGR cooler.

Caution

The Exhaust Gas Temperature Sensor 1 - G235- covers the

upper threaded connection on the turbocharger support and

must not be bent. It may not be removed.

– Remove the Exhaust Gas Temperature Sensor 1 - G235- .
– Remove the right axle shaft from the bevel box. Refer to ⇒ 

Suspension, Wheels, Steering; Rep. Gr.  40 .

– Remove the banjo bolt -item 24- 

⇒ Item 24 (page 273)

 from

the turbocharger support.

3. Turbocharger    

281

bocharger.

– Rotate the lower section of the support 90° and remove the

support downward from the upper section.

– Remove the heat shield on the exhaust manifold.
– Remove the exhaust manifold nuts.
– Remove the turbocharger and then turn it so that the intake

side is facing downward and the remove the turbocharger

downward.

Installing

Caution

Before installing, check if the oil return line decoupling element

is hidden and therefore stretched. If this is the case, there could

be micro tears which could result in leaks. If necessary, replace

the oil return line before installing the turbocharger.

– Install in reverse order of removal. Note the following:
♦ Insert the turbocharger with the pressure side upward.
♦ Position the charge air pipe connecting hose before securing

the turbocharger.

♦ Pay attention to the installation position of the Exhaust Gas

Temperature Sensor 1 - G235- . Refer to

⇒ Fig. ““Installed position, exhaust gas temperature sensor

with angled shaft”“ , page 276

 :

♦ Replace the banjo bolt for the turbocharger support and the

O-rings for the oil return line.

♦ Be careful not to overstretch the decoupling element for the oil

return line when installing the turbocharger support.

3.4

Vacuum Diaphragm with Charge Air

Pressure Actuator Position Sensor -

G581- , Replacing

Special tools and workshop equipment required
♦ Actuator Socket - 10mm - T10422A-
♦ Union Nut Socket - T40055-
♦ Ring Wrench 10x12mm - T10423-
♦ Vehicle Diagnostic Tester

Caution

The specified special tools, in particular the Actuator Socket -

10mm - T10422A- , are designed exclusively for use according

to the following work procedure and may not be used for other

screw connections. Higher torques can cause deformation.

282

 

 

 

 

 

 

 

Content   ..  422  423  424  425   ..