Volkswagen Golf Service & Repair Manual: Removing and installing turbocharger

Special tools and workshop equipment required

Engine bung set -VAS 6122-

Hose clip pliers -VAS 6362-

Release tool -T10527-

Release tool -T10527/1-

Removing

Note

Observe rules for cleanliness → Chapter.

Fit all heat shield sleeves in the same place when installing.

If a mechanical fault is discovered on the turbocharger (e.g. a destroyed compressor impeller), it is not sufficient to just renew the turbocharger. To avoid any subsequent damage, the following work must be carried out: Check air filter housing, air filter element and air inlet hoses for contamination.

Check the whole charge air path and charge air cooler for foreign objects.

If foreign objects are discovered in the charge air system, clean the charge air path and, if necessary, renew the charge air cooler.

Drain coolant → Chapter.

Unscrew bolts -arrows- and remove heat shield for right drive shaft.

Remove heat-shield sleeve.
Disconnect connector -arrow- from oil pressure switch for reduced oil pressure -F378-.

Remove bolts -arrows- and detach oil supply line -1- and oil return line -2-.

Unscrew bolt -2- and remove screw-type clip.
Remove bolt -1- and nuts -arrows- and tie up catalytic converter.

Release hose clips -1- and -2-, and remove air pipe.
Move air hoses clear at air pipe.
Detach connector from charge pressure sender -GX26-.

Release fasteners -arrows- using release tools -T10527- and -T10527/1-.
Remove air pipe -1-.

Press release tabs and disconnect hose -1- for activated charcoal filter.
Remove bolts -arrows- and detach crankcase breather hose.

Disconnect electrical connector -2-.
Remove bolts -arrows- and detach connection -1-.

Release hose clip -2- and detach coolant hose.
Remove bolts -arrows- and pivot coolant lines -1- to right side.

Unscrew bolts -arrows- and remove heat shield -1-.

Unscrew nuts -arrows- and remove turbocharger.

Installing

Installation is carried out in the reverse order; note the following:

Fit screwdriver -2- in recess -arrow- on turbocharger and lever out seal -1-.

Note

Renew seals, O-rings and securing nuts of cylinder head.

Renew clamps for attaching catalytic converter to turbocharger.

Fill turbocharger with engine oil at connection for oil supply line.

Secure all hose connections with hose clips meeting production standard → Electronic Parts Catalogue. After installing turbocharger, run engine for about 1 minute at idling speed to ensure that oil is supplied to turbocharger.

Electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations.
Replenish coolant → Anchor.

Removing and installing turbocharger