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Removing and installing turbocharger, engine code CJAA > < Removing and installing turbocharger

Golf Mk6

Removing and installing turbocharger, engine codes CBAA, CBBB, CBAB, CBBA, CBDB, CBDC, CBAC, CBDA
Removing and installing turbocharger, engine codes CBAA, CBBB, CBAB, CBBA, CBDB, CBDC, CBAC, CBDA
Special tools and workshop equipment required
t  Torque wrench -V.A.G 1331-
  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 intake pipe -1- and disconnect connector of position sender for charge pressure positioner -G581--2- from turbocharger.
–  Pull vacuum line -3- off turbocharger.
  N21-10174
–  Disconnect connector for exhaust gas temperature sender 1 -G235--1- from plenum chamber bulkhead and guide wire out of retainers.
  N26-10333
–  Unscrew oil supply line -arrow- from turbocharger.
  N21-10190
–  Remove securing bolt -1- from charge air pipe, loosen clamp -2- and pull off connecting hose at turbocharger as far as it will go.
–  Remove particulate filter → Chapter.
  N21-10193
–  Remove connecting pipe -A- to exhaust gas recirculation cooler.
  Caution
Exhaust gas temperature sender 1 -G235- conceals the upper bolt of the exhaust gas turbocharger support. The temperature sender must not be bent. It must therefore be removed.
–  Remove exhaust gas temperature sender 1 -G235-.
–  Pull right axle shaft off bevel box → Running gear, axles, steering; Rep. gr.40.
–  Remove banjo bolt → Item of turbocharger support.
  N21-10191
–  Unscrew upper bolt -arrow- from support on turbocharger.
–  Turn lower part of support 90° and pull support downwards off upper part.
–  Remove heat shield from exhaust manifold.
–  Unscrew securing nuts for exhaust manifold.
–  Take off turbocharger, turn it so that intake side faces downwards and remove turbocharger downwards.
Installing
  Caution
Before installing, check whether decoupling element of oil return line is bent and thus stretched. If this is the case, micro cracks can have formed and may cause leakage. If necessary, renew oil return line of turbocharger before installing.
–  Install in reverse order. In the process, note the following:
t  Fit turbocharger with pressure side facing upwards.
t  Position connecting hose of charge air pipe before bolting on turbocharger.
t  Note installation position of exhaust temperature sender 1 -G235- → Fig..
t  Renew banjo bolt for turbocharger support and O-rings for oil return line.
t  Do not overstretch decoupling element of oil return line when installing turbocharger support.
  N15-10436

Removing and installing turbocharger, engine code CJAA > < Removing and installing turbocharger