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Removing and installing parts of charge air cooling > < Charge air system with turbocharger

Leon Mk2

Removing and installing turbocharger with attachments
Removing and installing turbocharger with attachments
  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.
   
1 - Exhaust manifold
2 - Gasket
q   Renew.
q   Note installation position.
3 - Seal
q   Renew.
4 - Union, 30 Nm
5 - From oil filter bracket
q   For vehicles with engine code AJH: → Item.
q   For vehicles with engine code AWC: → Item.
6 - Oil supply line
q   Tighten to 25 Nm.
7 - To coolant circulation pump -V50- (AJH) or continued coolant circulation pump -V51- (AWC)
q   Coolant hose connection schematic diagram: engine code AJH → Chapter.
q   Coolant hose connection schematic diagram: engine code AWC → Chapter.
8 - Coolant return pipe
q   Tighten to 30 Nm.
9 - Union, 35 Nm
10 - Washer
11 - 25 Nm
12 - Vacuum hose
q   To charge pressure control solenoid valve -N75-.
q   Schematic diagram of turbocharging system: engine code AJH → Chapter.
q   Schematic diagram of turbocharging system: engine code AWC → Chapter.
13 - Banjo bolt, 25 Nm
14 - From cylinder block
q   Coolant hose connection schematic diagram: engine code AJH → Chapter.
q   Coolant hose connection schematic diagram: engine code AWC → Chapter.
15 - Coolant supply pipe
16 - 10 Nm
17 - Vacuum hose
q   To charge pressure control solenoid valve -N75-.
q   Schematic diagram of turbocharging system: engine code AJH → Chapter.
q   Schematic diagram of turbocharging system: engine code AWC → Chapter.
18 - Banjo bolt, 15 Nm
19 - Spacer sleeve
q   Only vehicles with manual gearbox.
20 - Support
q   Between turbocharger and cylinder block.
21 - From air filter
q   Schematic diagram of turbocharging system: engine code AJH → Chapter.
q   Schematic diagram of turbocharging system: engine code AWC → Chapter.
22 - To charge air cooler
q   Schematic diagram of turbocharging system: engine code AJH → Chapter.
q   Schematic diagram of turbocharging system: engine code AWC → Chapter.
23 - Plug, 15 Nm
24 - Oil return line
q   To sump → Item.
25 - Gasket
q   Renew.
26 - Turbocharger
q   The charge pressure regulating valve and charge pressure regulating valve pressure actuator are integral parts of turbocharger and cannot be individually replaced.
q   Checking charge pressure system: engine code AJH → Chapter.
q   Checking charge pressure system: engine code AWC → Chapter.
q   Before connecting the oil supply line fill turbocharger with engine oil via pipe union
q   After installing turbocharger, run engine for about 1 minute at idling and do not rev up immediately, this ensures that the turbocharger is fully primed with oil.
27 - Front exhaust pipe
28 - 35 Nm
q   Renew.
q   Coat threads and bolt head contact surface with high-temperature paste -G 052 112 A3-.

   

Removing and installing parts of charge air cooling > < Charge air system with turbocharger