volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

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Assembly overview - parts of charge air cooling > < Changing and adjusting vacuum unit on turbocharger - only vehicles with engine code: BLS from model year 2008

Golf Mk5

Removing and installing turbocharger
Removing and installing turbocharger
Special tools and workshop equipment required
t  Torque wrench -V.A.G 1331-
   
t  Lambda probe open ring spanner set -3337-
  W00-0206
t  Tool set -T10395-
  Caution
When a mechanical fault is found on the turbocharger, e.g. a destroyed compressor impeller, it is not only sufficient to renew the turbocharger. To prevent this from causing further damage, perform the following repairs:
t  Check air filter housing, air filter element and intake hoses for soiling.
t  Check complete charged air routing and charge air cooler for foreign objects.
If foreign objects are found in the charge air system, the charged air routing must be cleaned and the charge air cooler must be renewed, if necessary.
Removing
–  Remove noise insulation → General body repairs, exterior; Rep. gr.50.
Vehicles with four-wheel drive:
–  Remove front propshaft → Final drive 02D, 0AV; Rep. gr.39.
–  Remove right drive shaft → Running gear, axles, steering; Rep. gr.40.
Vehicles with particulate filter
–  Pull electrical connector off exhaust gas pressure sensor 1 -G450- in engine compartment and unscrew securing bolts.
–  Separate electrical connectors to particulate filter.
–  Remove subframe including steering and right drive shaft → Running gear, axles, steering; Rep. gr.40.
–  Remove particulate filter.
–  On vehicles with four-wheel drive remove the bevel box to reach the threaded connection for turbocharger support → 6-speed manual gearbox; Rep. gr.34.
Continuation for all vehicles:
  W00-10767
–  Disconnect fasteners -arrows- of coolant pipes for auxiliary heater, if part of original equipment.
  N21-10052
–  Unbolt pendulum support -arrows-.
–  Remove support and oil return line or combi support → Item for turbocharger.
–  Remove connecting pipe to exhaust gas recirculation cooler.
–  Separate charge pressure line from turbocharger.
–  Pull vacuum hose off turbocharger.
–  Separate oil supply line from turbocharger.
–  Unscrew securing bolts for exhaust manifold.
–  Tilt the engine forwards in lower mounting and remove turbocharger with exhaust manifold downwards.
Installing
–  Install in reverse order.
  Note
Torque setting of pendulum support → Chapter.
  N10-0444

Assembly overview - parts of charge air cooling > < Changing and adjusting vacuum unit on turbocharger - only vehicles with engine code: BLS from model year 2008