SM 8

Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
4-cylinder injection engine (1.4 l direct injection engine, turbocharger) - Edition 07.2015
21 – Turbocharging/supercharging
1 Turbocharger
Note
♦ Secure all hose connections with hose clips which conform to

production standard.
♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly.
♦ Charge air system must be free of leaks.
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♦ Renew self-locking nuts.
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♦ Spring-typeiseclip pliers - VAS 5024A- or hose clipupliers
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♦ Fill turbocharger
s with engine oil at oil supply line connection.
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♦ After installing turbocharger, run engine for about 1 minute at
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idle and do not rev up immediately. This ensures that the tur‐
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bocharger is fully primed with oil.
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Assembly overview - turbocharger ⇒ page 271 .
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Removing and installing turbocharger ⇒ page 275 .
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Removing and installing compressor housing and turbine housing

⇒ page 280 .
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Checking turbocharger vacuum unit ⇒ page 284 .

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Removing and installing vacuum unit for turbocharger

⇒ page 286 .
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Adjusting vacuum unit for turbocharger ⇒ page 288 .

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1.1 Assembly overview - turbocharger

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Part I ⇒ page 273

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Part II ⇒ page 274

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1. Turbocharger 271
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272 Rep. gr.21 - Turbocharging/supercharging

1.2 Part I
1 - Turbocharger with exhaust

manifold
❑ Removing and installing
⇒ page 275
compressor housing
and turbine housing
⇒ page 280 .
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❑ auRemoving and installing
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❑ Adjusting vacuum unit
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⇒ page 288 .
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Specified torques:
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❑ Securing bolts for vac‐

uum unit to turbocharg‐
er: 20 Nm. t to the co
❑ Lock nut to vacuum unit
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rod: 10 Nm.
2 - O-ring
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3 - Turbocharger air recircula‐

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5 - Connecting hose
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9 - Spring-type clip
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10 - Charge pressure control solenoid valve - N75-

11 - 10 Nm
12 - Connecting hose
13 - Connecting hose
14 - Bracket
❑ At coolant line.
1. Turbocharger 273
1.3 Part II
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⇒ Item 20 (page 275) .

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2 - 8 Nm
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3 - 8 Nm
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4 - Coolant pipe
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5 - Bracket
6 - 8 Nm
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7 - O-ring
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9 - 20 Nm
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10 - 8 Nm
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11 - Coolant pipe
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14 - Oil return pipe
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15 - 8 Nm
16 - Turbocharger with ex‐
haust manifold
⇒ page 275
compressor housing
and turbine housing ⇒ page 280 .
Note
♦ The studs need to be renewed as

well as the securing nuts.
♦ Screw studs into cylinder head
until they project only by 25 mm.
17 - Gasket
❑ Renew
18 - 25 Nm
❑ Renew
❑ Coat studs of exhaust manifold with high-temperature paste.
Note
♦ The studs need to be renewed as

well as the securing nuts.
♦ Screw studs into cylinder head
until they project only by 25 mm.

19 - Bracket
20 - Banjo bolt
❑ Renew
Note
Beginning with model year 2009 ►

revised oil supply pipe installed.
Note differing specified torques.
Specified torques:
❑ Banjo bolt on cylinder block 30 Nm
❑ Banjo bolt on timing housing 20 Nm.
21 - Seal
❑ Renew
1.4 Removing and installing turbocharger
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Special tools and workshop equipment required
♦ Hose clip pliers - VAS 6340-
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♦ Torque wrench (5…50 Nm) - V.A.G 1331- d by
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1. Turbocharger
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♦ Hose clamps up to 25 mm - 3094-
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: agen
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♦ Check air filter housing, air filter element and intake hoses V gu
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♦ Check complete charged air routing and charge ss air cooler c
for foreign objects.
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If foreign objects are found in the charge air system, the charg‐
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Before carrying out further work, disconnect battery earth strap.
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Check whether a coded radio is fitted. Obtain anti-theft coding first

if necessary.
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– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐
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– Clamp off coolant hoses to turbocharger using hose clamps

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– Remove securing bolts -1- from engine cover panel.

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– Detach coolant hoses -2- at engine cover panel and pull en‐ Cop py
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– Pull connector -1- off turbocharger air recirculation valve -

N249- .
– Detach hoses -2- at pressure pipe and open wiring guide -3-.
– Pull hoses -1- off intake connecting pipe for turbocharger.

– Pull connector -2- off charge air pressure sender - G31- with
intake air temperature sender 2 - G299- and remove securing
bolts -3-.
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– Press retaining clips -1- outwards and pull pressure pipe -2-
upwards.
– Then pull pressure pipe -2- off turbocharger.
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– Unscrew securing bolts -arrows- and remove heat shield from

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1. Turbocharger
– Detach coolant hoses -1- from coolant pipes.

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– Unscrew securing bolts -2- and remove coolant pipe yV
o-3-.
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– Remove poly V-belt ⇒ page 51 . horis tee
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– Remove air conditioner compressor ⇒ Heating,
ss air condition‐
ing; Rep. gr. 87
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The air conditioning system lines must not be opened.
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– Secure air conditioner compressor to lock carrier.
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– Ensure that lines are not kinked.
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– Unbolt securing nuts at turbocharger -arrows-.
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– Unclip wiring -1- from catalytic converter.
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– Disconnect connectors -2-. cted agen
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– Unscrew securing nuts -3- and remove seal.

– Remove catalytic converter downwards.
– Remove securing bolts -arrows- from heat shield and pull

shield off exhaust manifold in direction of -arrow-.
– Remove securing bolts -1- for oil supply pipe -3-.

– Unscrew banjo bolt -2- from cylinder block and remove oil
supply pipe.
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– Unscrew securingautbolt -4- and remove bracket -5-. or
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– Unscrew securing bolts -1- for oil return pipe -2- and remove
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The alternator must only be loosened if the securing nuts have
inner drive splines.
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– Loosen alternator ⇒ Electrical system; Rep. gr. 27 ; Removing
ss
and installing alternator .
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– Remove all securing nuts -1- from exhaust manifold and pull
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bracket -3- off studs.
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– Remove exhaust manifold together with turbocharger -2- from

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♦ The studs need to be renewed as well as the securing nuts.

♦ Screw studs into cylinder head until they project only by
25 mm.
– Fit turbocharger together with exhaust manifold and new gas‐

ket to cylinder head.
1. Turbocharger 279
– Tighten securing nuts to 25 Nm in sequence as specified.

Perform further installation in reverse order, paying attention to
the following:
♦ Renew seals, gaskets and self-locking nuts.
♦ Fill turbocharger with engine oil at oil supply line connection.
♦ After installing turbocharger, run engine for about 1 minute at
idling speed to ensure that oil is supplied to turbocharger.
Specified torques:
Assembly overview - part I, turbocharger ⇒ page 273 .
Assembly overview - part II, turbocharger ⇒ page 274 .
Assembly overview - catalytic converter and add-on parts
⇒ page 346
– Top up coolant if necessary ⇒ page 157 .
– Attach coolant hoses -2- to engine cover panel and press en‐
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gine cover panel downwards.
– Tighten securing bolts -1- for engine cover panel to 8 Nm.
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1.5 Removing and installing compressor
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housing and turbine housing ab

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Note
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Please use a suitable repair kit for the following work sequence
⇒ Electronic Parts Catalogue (ETKA) .
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♦ Engine bung set - VAS 6122-

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♦ Torque wrench - V.A.G 1331-
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♦ Hot air blower - V.A.G 1416-
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– Remove turbocharger ⇒ page 275 .

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– Checking turbocharger vacuum unit ⇒ page 284 .
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– Seal all openings in turbocharger -arrows- with suitable plugs
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– Remove circlip -1- using screwdriver -2-.

– Pull threaded rod -3- off stud.
Caution
In order to prevent the exhaust manifold from becoming dam‐

aged, always use aluminium protective jaws -1- for the vice!
1. Turbocharger 281
– Clamp exhaust manifold -2- in vice as shown in illustration.
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– Unscrew securing nut -1- of clamp -2-, andsremove
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If the turbine housing is still tightly secured to the compressor
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housing after the clamp -2- has been removed:
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• Do not use leverage tools!
spec
• Always use the hot air blower - V.A.G 1416- to loosen the
t to the co
connection in order to prevent the centring pin on the tur‐
bine housing from becoming damaged.
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If the compressor housing is still tightly secured to the turbine
ss
housing due to deposits:
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– Using hot air blower - V.A.G 1416- , apply heat evenly all f inform
mer
around the connection point between the compressor housing

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and the turbine housing for about 2 minutes.

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– Carefully remove compressor housing upwards.

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If the centring pin -arrow- is shared off or damaged, the turbo‐

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charger needs to be renewed together with the exhaust manifold.

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Place compressor housing on workbench as shown in illustra‐
tion in order to prevent any damage to the turbine wheel!
Do not use compressed air to clean the compressor housing!

– Clean compressor housing all around -arrows- using, for ex‐

ample, brake cleaner and sandpaper (220 to 1000 grade).
– Remove exhaust manifold from vice.
Installing
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Caution yV
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In order to prevent the exhaust
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– Clamp new exhaust manifold -2- in vice as shown in illustra‐
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– Fit compressor housing onto turbine housing.
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Make sure that centring pin -1- of turbine housing engages in hole
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-2- of compressor housing. Prote AG.
1. Turbocharger 283
– Using a feeler gauge -1-, measure gap -arrow- between com‐

pressor housing and turbine housing.
The gap must be even all around and must measure ≤ 1.2 mm.
– Fit new clamp around both flanges.
Note
♦ The stud may bend slightly when the securing nut is tightened
to 9 Nm. This is normal and not critical.
♦ Therefore, a new clamp with a new stud must always be used
when assembling.
– Align clamp so that centre of stud is flush with marking

-arrow- on compressor housing.
– Tighten new securing nut -1- of clamp -2- to 9 Nm.
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– Apply light hammer blows
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– Then, tighten securing nut again to 9 Nm.

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– Push threaded rod -1- of vacuum unit onto stud -2-.

– Push new circlip -3- into groove in stud.
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– Adjusting vacuum unit for turbocharger ⇒ page 288 .

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– Installing turbocharger ⇒ page 275 .

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1.6 Checking vacuum unit for turbocharger

Removing and installing vacuum unit for turbocharger
⇒ page 286 .
Adjusting vacuum unit for turbocharger ⇒ page 288 .

♦ Hand vacuum pump - VAS 6213-
Test prerequisites
♦ The hose from the turbocharger via the charge pressure con‐
trol solenoid valve - N75- to the vacuum unit must have
through-flow and be free of leaks.
♦ Charge pressure control solenoid valve - N75- OK.
Procedure
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– Unscrew bolts -arrows- and remove heat shield for turbo‐
charger. en AG. V
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– Pull hose -arrow- off vacuum unit.

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1. Turbocharger 285
– Place hose -2- of hand-operated vacuum pump - VAS 6213-

onto vacuum unit connection.
– Push sliding ring -1- on hand vacuum pump - VAS 6213- to
stop in direction of -arrow-.
– Operate hand vacuum pump - VAS 6213- repeatedly.
Caution
Excessive pressure may damage the vacuum unit.

The pressure must not exceed 800 mbar!
Note
The illustration shows the installation position with the turbo‐

charger removed. agen
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– Observe operating rodtho-1- of turbocharger vacuum unit.
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The operating rod must move from approx. 300 mbar.
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♦ At approx. 800 mbar, the operating rod must reach the end of
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– Vent hand-operated vacuum pump - VAS 6213- -arrow A-.

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♦ The operating rod must move in the opposite direction.

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Check the movement sequence of the operating rod in the entire

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adjustment range. It must move continuously and smoothly.

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Assembly is performed in the reverse order of removal.

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Specified torque of heat shield for turbocharger: 8 Nm opyri
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1.7 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 ⇒ page 303 .

charger.
– Unscrew bolts -2- and remove retaining clip -1-.
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– 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.
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– Unscrew bolt -4- and remove crankcase breather hose from

turbocharger -arrow- and lay it to side.
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Note
mer
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The positions labelled -1, 2, 3- should be disregarded.

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1. Turbocharger 287
– 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.
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– Lever off securing clip -2- and pull threaded piece -1- of oper‐ c
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ating rod off operating lever pin -3-.

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– Remove hose -2- from turbocharger vacuum unit.

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– Unscrew bolts -1- and remove turbocharger vacuum unit -3-.

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Installing
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Specified torques ⇒ page 273 .

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Specified torque of heat shield for turbocharger: 8 Nm

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Installation is performed in the reverse order of removal.

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Note
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Ensure securing clip seats correctly in the pin groove.
– Adjusting vacuum unit for turbocharger ⇒ page 288 .
1.8 Adjusting vacuum unit for turbocharger

Special tools and workshop

equipment required
♦ Universal dial gauge brack‐
et - VW 387-
♦ Hand vacuum pump - VAS
6213-
♦ Pressure regulating valve -
VAS 6342-
♦ Turbocharger tester -
V.A.G 1397A-
♦ Dial gauge set, 4-part - VAS
6341-
♦ Torque wrench - V.A.G
1783-
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♦ Open end spanner insert (10 mm) - V.A.G 1783/1-

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Procedure
atio
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– Detach coolant hose -2- from engine cover panel.

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1. Turbocharger 289
– Pull oil dipstick out.

– Unscrew bolts -arrows- and remove engine cover panel.
– Remove air filter housing ⇒ page 303 .

charger.
– Unscrew bolts -2- and remove retaining clip -1-.
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– Pull connector -3- off charge air pressure sender - G31- .
– Release catches -arrows- and pull air pipe first off throttle valve
agen
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module - J338- and then off turbocharger. Volksw not
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– Lay hoses at air pipe to side. oris tee
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– Unscrew bolt -4- and remove crankcase breather hose from

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turbocharger -arrow- and lay it to side.

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The positions labelled -1, 2, 3- should be disregarded.

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– 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.
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The position
ss a labelled -2- should be disregarded.
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– Unscrew bolts -2- and -3-, then remove retaining plate.
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The positions labelled -1- and -4- should be disregarded.
rrectness of i
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– Remove hose -2- from turbocharger vacuum unit.

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– Connect test and measuring instruments together as illustra‐
ted and connect to connection “II” of turbocharger tester -
V.A.G 1397A- and to turbocharger vacuum unit.
– Close lever -1- on pressure regulating valve - VAS 6342- .

– Move slide ring -2- of hand-operated vacuum pump - VAS
6213- in direction of -arrow-.
– Switch on turbocharger tester - V.A.G 1397A- and set sliding
switch to position “II”.
– Operate hand vacuum pump - VAS 6213- several times until
a pressure of approx. 800 mbar is attained.
Caution
Excessive pressure may damage the vacuum unit.

The pressure must not exceed 800 mbar!
1. Turbocharger 291
olkswagen AG
en AG. V
– Vent hand-operated vacuum opump ksw - VAS 6213- -arrow eA-
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– Repeat process 5sstimes.
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– Secure universal dial gauge bracket - VW 387- to turbocharger
pt
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as illustrated.
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– Secure dial gauge - VAS 6341/1- with flat pickup - VAS 6341/4-
rrectne
to universal dial gauge bracket - VW 387- .
– Set dial gauge - VAS 6341/1- to 1 mm pretension at 0 bar.
ss o
– Turn graduated scale of dial gauge - VAS 6341/1- to “0”.
cial p
f inform
mer
pressure of 385 mbar is attained on turbocharger tester -
atio
m
V.A.G 1397A- .
o
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Specification on dial gauge - VAS 6341/1- : 1 mm stroke.
Note
♦ If specification is not attained, loosen lock nut -4-.

♦ Lever up securing clip -2- and pull threaded piece -1- off op‐
erating lever pin -3-.
♦ Turn threaded piece on operating rod until specification is at‐
tained. Position threaded piece onto operating lever pin to
perform check.
♦ If the bore of the threaded piece does not fit onto the pin in this
position, the threaded piece may be rotated one-half turn in
either direction.
♦ Secure threaded piece with securing clip -2- to operating lever
pin and tighten lock nut -4-.
Checking adjustment of vacuum unit

– Set dial gauge - VAS 6341/1- to 1 mm pretension at 0 bar.
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Measurement 1:
– Operate hand vacuum pump - VASn 6213-AG. Volkseveral
swagen Atimes until
a pressure of 750…800 mbarolkis
swattained
age on turbocharger
G do
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– Reduce pressure to th375
o mbar on pressure regulating valve - or
au
VAS 6342- . ss ac
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– Read stroke on dial gauge - VAS 6341/1- and make a note.

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– Reduce pressure to 0 mbar on pressure regulating valve - VAS

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6342- .
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V.A.G 1397A- .
es, in part or in w
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– Calculate average by adding values “1” and “2” and dividing
rrectness of i
sum by 2.
l purpos
Specification: 1 mm
Measurement 2:
nform
ercia

m
a pressure of 750…800 mbar is attained on turbocharger test‐

at
om
io
er - V.A.G 1397A- .
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– Reduce pressure to 475 mbar on pressure regulating valve -

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VAS 6342- .
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– Reduce pressure to 0 mbar on pressure regulating valve - VAS
t. C rig
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6342- . p by
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– Turn graduated scale of dial gauge - VAS 6341/1- to “0”. Prote AG.

V.A.G 1397A- .
– Calculate average by adding values “1” and “2” and dividing
sum by 2.
Specification: 5 mm
1. Turbocharger 293
– If specifications are not attained, repeat adjustment proce‐

dure.
Specified torques ⇒ page 273 .
Specified torque of heat shield for turbocharger: 8 Nm
Assembly is performed in the reverse order of removal.
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2 Charge air system
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♦ Spring-type clip pliers - VAS 5024A- or hose clip pliers - VAS
t to the co
6340- are recommended for installation of spring-type clips.
rrectne
♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly.
ss o
cial p
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♦ Charge air system must be free of leaks.
inform
mer
atio
Assembly overview - charge air system ⇒ page 295 .
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Removing and installing intake manifold charge air cooler
thi
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⇒ page 296
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2.1 Assembly overview - charge air system

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1 - Auxiliary radiator for charge p by
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air system
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❑ Remove cooler to re‐
move ⇒ page 163 .
in the Tiguan and Pas‐
sat ⇒ page 167 .
2 - O-ring
❑ Renew if damaged.
3 - Upper coolant hose
❑ Coolant hose schematic
diagram ⇒ page 156 .
4 - Spring-type clip
with hose clip pliers -
VAS 6340- .
5 - Connecting pipe
6 - Coolant hose
❑ To expansion tank.
7 - Protective grommet
8 - Coolant hose
❑ To turbocharger.
9 - Coolant hose
10 - Intake manifold
⇒ page 308
11 - Gasket
❑ Renew if damaged.
12 - Sealing strip
❑ Make sure it is properly
seated when installing the charge air cooler.
2. Charge air system 295

13 - Charge air cooler

❑ Removing and installing ⇒ page 296
❑ To remove, remove intake manifold ⇒ page 308 .
14 - 7 Nm
❑ When installing, first evenly tighten by hand and then tighten to specified torque.
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15 - Connecting pipe ksw
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16 - Coolant hose ise d b ara
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❑ Coolant hose auth schematic diagram ⇒ page 156 . eo
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17 - Coolant hose
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❑ Coolant hose schematic diagram ⇒ page 156 .
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18 - 10 Nm
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19 - 10 Nm
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20 - Coolant circulation pump - V50-
spec
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❑ Removing and installing ⇒ page 173
t to the co
21 - Bracket
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22 - 20 Nm
rrectness of i
23 - Coolant pipe
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24 - 10 Nm
nf
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25 - Lower coolant hose orm

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2.2 Removing and installing intake manifold

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charge air cooler

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♦ Hose clip pliers - VAS 6340-
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♦ Support - 3250-

Removing
– Remove intake manifold ⇒ page 308 .
– Unscrew securing bolts for charge air cooler in specified se‐ gen AG. Volkswagen AG
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– Pull charge air cooler out of intake manifold. rise nte
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Charge air cooler is installed into intake manifold using a work‐
wit
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shop press.
h re
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spec
t to the co
– Push sealing strip -1- in -direction of arrow- onto edge of
charge air cooler.
rrectne
– Check new gasket is seated correctly on intake manifold.
s
– Push charge air cooler into intake manifold to stop.
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o
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Do not tilt charge air cooler when installing it.
nform
mer
atio
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Note
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♦ Align intake manifold on table of workshop press.

iv
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♦ The housing of the charge air cooler -1- must be horizontal.
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♦ Use, for example, a wooden block as a base.
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t. rig
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pyri by
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– Position support - 3250- centrally on charge air cooler. Prote AG.
– Carefully lower ram of workshop press until housing of charge

air cooler -1- lies on intake manifold -2-.
– Screw securing bolts in evenly until bolt heads make contact.

– Tighten securing bolts to 7 Nm in sequence specified -A- to
-F-.
– Install intake manifold ⇒ page 308 .
Further installation is performed in the reverse order of removal.
2. Charge air system 297

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Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...

♦ Secure all hose connections with hose clips which conform to

Removing and installing compressor housing and turbine housing

Checking turbocharger vacuum unit ⇒ page 284 .

Removing and installing vacuum unit for turbocharger

Adjusting vacuum unit for turbocharger ⇒ page 288 .

1.1 Assembly overview - turbocharger

Part I ⇒ page 273

Part II ⇒ page 274

272 Rep. gr.21 - Turbocharging/supercharging

1 - Turbocharger with exhaust

charger ⇒ page 286 .

❑ Adjusting vacuum unit

❑ Securing bolts for vac‐

3 - Turbocharger air recircula‐

tion valve - N249-

6 - Intake connecting pipe

10 - Charge pressure control solenoid valve - N75-

❑ Note specified torques

⇒ Item 20 (page 275) .

♦ The studs need to be renewed as

♦ The studs need to be renewed as

274 Rep. gr.21 - Turbocharging/supercharging

Beginning with model year 2009 ►

1.4 Removing and installing turbocharger

♦ Hose clamps up to 25 mm - 3094-

When a mechanical fault is found on the turbocharger, e.g. a

Check whether a coded radio is fitted. Obtain anti-theft coding first

– Clamp off coolant hoses to turbocharger using hose clamps

– Remove securing bolts -1- from engine cover panel.

276 Rep. gr.21 - Turbocharging/supercharging

– Pull connector -1- off turbocharger air recirculation valve -

– Pull hoses -1- off intake connecting pipe for turbocharger.

– Unscrew securing bolts -arrows- and remove heat shield from

– Detach coolant hoses -1- from coolant pipes.

– Secure air conditioner compressor to lock carrier.

– Unclip wiring -1- from catalytic converter.

– Unscrew securing nuts -3- and remove seal.

– Remove securing bolts -arrows- from heat shield and pull

278 Rep. gr.21 - Turbocharging/supercharging

– Remove exhaust manifold together with turbocharger -2- from

♦ The studs need to be renewed as well as the securing nuts.

– Fit turbocharger together with exhaust manifold and new gas‐

– Tighten securing nuts to 25 Nm in sequence as specified.

housing and turbine housing ab

Special tools and workshop equipment required

♦ Engine bung set - VAS 6122-

280 Rep. gr.21 - Turbocharging/supercharging

♦ Torque wrench - V.A.G 1331-

– Remove turbocharger ⇒ page 275 .

– Remove circlip -1- using screwdriver -2-.

In order to prevent the exhaust manifold from becoming dam‐

– Clamp exhaust manifold -2- in vice as shown in illustration.

• Do not use leverage tools!

around the connection point between the compressor housing

and the turbine housing for about 2 minutes.

– Carefully remove compressor housing upwards.

If the centring pin -arrow- is shared off or damaged, the turbo‐

charger needs to be renewed together with the exhaust manifold.