Volkswagen Workshop Service and Repair Manuals

Removing and installing vacuum unit for turbocharger Removing –  Detach coolant hose -2- from engine cover panel.

–  Pull oil dipstick out. –  Unscrew bolts -arrows- and remove engine cover panel. –  Remove air filter housing → Chapter.

–  Unscrew bolts -arrows- and remove heat shield for turbocharger. –  Unscrew bolts -2- and remove retaining clip -1-.

–  Pull connector -3- off charge air pressure sender -G31-. –  Release catches -arrows- and pull air pipe first off throttle valve module -J338- and then off turbocharger. –  Lay hoses at air pipe to side.

–  Unscrew bolt -4- and remove crankcase breather hose from turbocharger -arrow- and lay it to side.   Note The positions labelled -1, 2, 3- should be disregarded.

–  Clamp off coolant hoses using hose clips -3094- as illustrated. –  Remove bolts -1, 3, 4, 5-. –  Pull coolant lines off turbocharger and lay to side.   Note The position labelled -2- should be disregarded.

–  Unscrew bolts -2- and -3-, then remove retaining plate.   Note The positions labelled -1- and -4- should be disregarded.

–  Lever off securing clip -2- and pull threaded piece -1- of operating rod off operating lever pin -3-.   Note The position labelled -4- should be disregarded.

–  Remove hose -2- from turbocharger vacuum unit. –  Unscrew bolts -1- and remove turbocharger vacuum unit -3-. Installing Specified torques → Chapter. Specified torque of heat shield for turbocharger: 8 Nm Installation is performed in the reverse order of removal. –  Install new securing clip for operating rod.   Note Ensure securing clip seats correctly in the pin groove. –  Adjusting vacuum unit for turbocharger → Chapter.