Volkswagen Workshop Service and Repair Manuals

Special tools, testers and auxiliary items

• ◆ Jointed spanner 3205 (Engine code AAZ)
• ◆ V.A.G 1331 Torque wrench (5...50 Nm)
• ◆ Grease G 000 500

Engine code 1Z, AHU

Engine code AFN

Engine code AAZ => Page 21-24

Removing

• ‒ With ignition switched off disconnect battery earth strap.

Note:

If necessary the anti-theft coding for the radio must be obtained first.

• ‒ → Remove hoses between intake manifold/turbocharger -1- and turbocharger/air cleaner -2-.
• ‒ Pull off red hose (or remove banjo bolt) for charge pressure control solenoid valve (N75) on turbocharger.
• ‒ Disconnect exhaust pipe from turbocharger.
• ‒ Disconnect oil supply pipe from turbocharger and securing clip from intake manifold.
• ‒ Remove turbocharger/cylinder block support.
• ‒ Disconnect oil return pipe on turbocharger.

• ‒ → Remove securing nut -1- from below and securing bolts -2- from above.
• ‒ Lift turbocharger out, upwards.
• ‒ Pull blue hose for charge pressure valve off pressure unit.

Installing

• ‒ Install blue hose for charge pressure valve on pressure unit and secure with a clamp.

• ‒ → Grease securing bolts -2- threads and head contact surfaces with G 000 500 grease.
• ‒ Fit turbocharger on exhaust manifold and tighten securing bolts -2- handtight.
• ‒ Install securing nut -1- and tighten to
       20 Nm.
• ‒ Tighten securing bolts -2- to
       35 Nm.
• ‒ Install turbocharger/cylinder head support and tighten to
       25 Nm.
• ‒ Install oil return pipe with new seal and tighten to
       30 Nm.
• ‒ Install front exhaust pipe with new gasket onto flange and tighten to
       25 Nm.
• ‒ Fill the turbocharger with engine oil via the oil supply connection.
• ‒ Install oil supply pipe and tighten to
       25 Nm.
• ‒ Tighten oil supply pipe support to
       10 Nm.
• ‒ Install red hose for charge pressure control solenoid valve (N75) on turbocharger and secure with clamp (or banjo bolt with new seal and tighten to
       15 Nm.
• ‒ Insert O-ring into intake pipe, then install intake pipe on turbocharger and tighten to
       10 Nm.
• ‒ Install pressure pipe.
• ‒ After installing the turbocharger, run engine for approx. 1 minute at idling speed, do not rev. up immediately. This ensures the turbocharger is properly lubricated.

Engine code AFN

Removing

• ‒ With ignition switched off disconnect battery earth strap.

Note:

If necessary the anti-theft coding for the radio must be obtained first.

• ‒ Remove engine cover.
• ‒ → Remove pressure pipe turbocharger/charge air cooling -1- and intake pipe turbocharger/air cleaner -2-.
• ‒ Pull charge pressure control vacuum pipe off pressure unit.

• ‒ Disconnect oil supply pipe from turbocharger and securing clip from intake manifold.
• ‒ Disconnect exhaust pipe from turbocharger.
• ‒ Remove turbocharger/cylinder block support.
• ‒ Disconnect oil return pipe on turbocharger.
• ‒ → Remove securing nuts -1- from below and securing nut -2- from above.
• ‒ Lift turbocharger out, upwards.

Installing

• ‒ → Grease threads of studs on exhaust manifold and turbocharger with G 000 500 grease.

• ‒ → Fit turbocharger on exhaust manifold and tighten securing bolts -2- handtight.
• ‒ Install securing nuts -1- and tighten to
       25 Nm.
• ‒ Install oil return pipe with new seal and tighten to
       30 Nm.
• ‒ Install bracket turbocharger/cylinder head and tighten to
       M8: 25 Nm
       M10: 30 Nm
• ‒ Tighten securing nut -2- to
       25 Nm.
• ‒ Install front exhaust pipe with new gasket onto flange and tighten to
       25 Nm.
• ‒ Fill the turbocharger with engine oil via the oil supply connection.
• ‒ Install oil supply pipe and tighten to
       25 Nm.
• ‒ Tighten oil supply pipe support to
       10 Nm.
• ‒ Insert O-ring into intake pipe and tighten intake pipe to
       10 Nm
  on turbocharger and intake manifold.
• ‒ Connect vacuum hose to charge pressure control pressure unit.
• ‒ Install turbocharger/charge air cooling pressure pipe and turbocharger/air cleaner intake pipe.
• ‒ After installing the turbocharger, run engine for approx. 1 minute at idling speed, do not rev. up immediately. This ensures the turbocharger is properly lubricated.

Engine code AAZ

Removing

• ‒ With ignition switched off disconnect battery earth strap.

Note:

If necessary the anti-theft coding for the radio must be obtained first.

• ‒ Remove hoses between intake manifold/turbocharger and turbocharger/air cleaner.
• ‒ Disconnect oil supply pipe from turbocharger and securing clip from intake manifold.
• ‒ Disconnect oil return pipe on turbocharger.
• ‒ Disconnect exhaust pipe from turbocharger and exhaust manifold support.

• ‒ → Remove the 3 securing bolts -arrows- between turbocharger and exhaust manifold (with ring spanner or jointed spanner 3205).

Installing

When installing observe the following:

• ‒ Fit turbocharger and tighten exhaust pipe securing nuts so that the turbocharger can still be moved slightly.
• ‒ Fit the 3 securing bolts and tighten fully. Then tighten the nuts on exhaust pipe.
• ‒ Before attaching the oil supply pipe, fill the connections on the turbocharger with engine oil.

• ‒ After installing the turbocharger, run engine for approx. 1 minute at idling speed, do not rev. up immediately. This ensures the turbocharger is properly lubricated.