Volkswagen Workshop Service and Repair Manuals

Observe rules for cleanliness .

Engine codes 1Z, AHU, ALE => Page 21-2

Engine codes AFN, AVG

Engine code AAZ

Turbocharger hose connections => Page 21-15 .

Notes:

• ◆ All hose connections are secured with clips.
• ◆ Charge air system must be free of leaks.
• ◆ Renew self-locking nuts.
• ◆ Before screwing on oil supply pipe fill turbocharger at connection with engine oil.

Engine codes 1Z, AHU, ALE

• Intake manifold
• ◆ Engine codes ALE
• From charge air cooler
• Intake manifold
• ◆ Engine codes 1Z, AHU
• Hose
• ◆ Black
• ◆ To diesel direct injection system control unit (J248)
• Gasket
• ◆ Renew
• ◆ Coating (beading) towards intake manifold
• 25 Nm
• Gasket
• ◆ Note installation position

• Washer
• 10 Nm
• ◆ Install with D6
• Circlip
• Pressure unit
• ◆ For charge pressure regulating valve
• ◆ Checking
• ◆ Removing and installing
  => Page 21-33
• Hose
• ◆ Blue
• ◆ To charge pressure control solenoid valve (N75) => Page 21-15 , turbocharger hose connections
• Seal
• ◆ Renew
• Banjo bolt, 15 Nm

• From air cleaner
• O-ring
• ◆ Renew if damaged
• 10 Nm
• Banjo bolt, 30 Nm
• Oil return pipe
• ◆ To cylinder block
• 20 Nm
• Gasket
• ◆ Renew
• Retainer
• Hose
• ◆ rot
• ◆ To charge pressure control solenoid valve (N75) => Page 21-15 , turbocharger hose connections

• Turbocharger
• ◆ Removing and installing
  => Page 21-18
• ◆ Checking boost pressure
  => Page 21-26
• To charge air cooler
• Front exhaust pipe
• Oil supply pipe
• ◆ From oil filter bracket
  => Page 17-3 , item 8
• ◆ Before installing, fill turbocharger with engine oil via oil supply pipe connection
• Heat shield
• Exhaust manifold
• 35 Nm
• ◆ Renew
• ◆ Coat threads and bolt head seating surface with G000500

Engine codes AFN, AVG

• Exhaust manifold
• Intake manifold
• ◆ With exhaust gas recirculation valve
• From charge air cooler
• Gasket
• ◆ Renew
• ◆ Coating (beading) towards intake manifold
• 25 Nm
• Gasket
• ◆ Note installation position
• Retainer
• ◆ For heat shield item 12
• Washer
• From air cleaner
• 10 Nm

• Hose
• ◆ To charge pressure control solenoid valve (N75) => Page 21-15 , turbocharger hose connections
• Heat shield
• ◆ Engage in bracket item 7
• Turbocharger
• ◆ Removing and installing
  => Page 21-18
• ◆ Checking charge pressure

=> Repair group 23; Checking components and function; Checking charge pressure control

• Pressure unit
• ◆ For charge pressure control
• ◆ Integral part of turbocharger cannot be replaced
• O-ring
• ◆ Renew if damaged
• Seal
• ◆ Renew

• Banjo bolt, 30 Nm
• Oil return pipe
• ◆ To cylinder block
• 20 Nm
• Gasket
• ◆ Renew
• 30 Nm
• Retainer
• To charge air cooler
• Front exhaust pipe
• Oil supply pipe
• ◆ From oil filter bracket
  => Page 17-3 , item 8
• ◆ Before installing, fill turbocharger with engine oil via oil supply pipe connection
• 25 Nm
• ◆ Renew
• ◆ Coat threads and bolt head seating surface with G 000 500

Engine code AAZ

Note:

• ◆ The charge pressure control is switched off during part throttle openings by the automatic glow period control unit via the exhaust gas recirculation two-way valve.
• ◆ Checking two-way valve
  => Page 26-24

• Gasket
• ◆ Coating (beading) towards intake manifold
• Intake manifold
• 45 Nm
• ◆ Coat threads and bolt head seating surface with G000500
• ◆ Renew
• Gasket
• ◆ Note installation position
• Exhaust manifold

• 25 Nm
• To crankcase breather
• From air cleaner
• Turbocharger
• ◆ Removing and installing
  => Page 21-18
• ◆ Checking boost pressure
  => Page 21-26
• Charge pressure regulating valve
• ◆ Integral part of turbocharger cannot be replaced
• ◆ Hose/pipe connections
  => Page 21-15
• Oil return pipe
• ◆ To cylinder block
• Sealing ring
• ◆ Renew
• 50 Nm
• 40 Nm

• Gasket
• Exhaust pipe
• 25 Nm
• Oil supply pipe
• ◆ From oil filter bracket
  => Page 17-3 , item 8
• ◆ Before installing, fill turbocharger with engine oil via oil supply pipe connection
• Air hose