Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤

4-cylinder injection engine (2.0 l engine, turbocharger) - Edition 08.2014

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. The oil seals and seal‐
ing surfaces must be oiled lightly only for plug-in connector
⇒ page 242 .
♦ Charge air system must be free of leaks.
♦ Renew self-locking nuts.
♦ Hose clip pliers - VAS 6499- or hose clip pliers - V.A.G 1921-
are recommended for installation of spring-type clips.

cardiagn.com
♦ Fill turbocharger with engine oil at oil supply line connection.
♦ After installing the turbocharger, run engine for about 1 minute
at idling speed and do not rev up immediately to ensure that
the turbocharger is fully primed with oil.

Fitting hose connections with plug-in connectors ⇒ page 242 AG. Volkswagen AG d
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Assembly overview - turbocharger ⇒ page 243 . ised b ara
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Removing and installing turbocharger ⇒ page 247 . aut ra
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Checking turbocharger vacuum unit ⇒ page 255 .

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Adjusting vacuum unit for turbocharger ⇒ page 256 .

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Removing and installing vacuum unit for turbocharger
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⇒ page 256 .

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1.1 Fitting hose connections with plug-in
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connectors

Caution rrectness of i
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The seal in the plug-in connector can be damaged if the se‐

curing clip is in the locked position when fitting the connector.
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This can cause leakage. Observe installation instructions.

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– Release plug-in connector by pulling out retaining clip

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-arrow-. Separate hose/pipe without tools.

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– If renewed, place seal in groove of charge air hose. Make sure rig ht
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complete circumference and that it is not twisted.
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– Lubricate sealing surface and seal with oil.

242 Rep. gr.21 - Turbocharging/supercharging

 Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
4-cylinder injection engine (2.0 l engine, turbocharger) - Edition 08.2014
AG. Volkswagen AG d
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– Bring retaining clip to release by V position -1-.
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– Push charge air hose ut
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– Bring securing clip to locking position -2- and then push charge
s

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air hose again.
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– Check if plug-in connector seats correctly and is properly en‐
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following “5 rules” for cleanliness:
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♦ Thoroughly clean all unions and surrounding areas before dis‐
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♦ Place removed parts on a clean surface and cover. Use only
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lint-free cloths. Prote AG.

♦ Carefully cover opened components or seal if repairs cannot

be carried out immediately.
♦ Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have not been stored in their packing (e.g. in
tool boxes etc.).
♦ When system is open: do not work with compressed air if this
can be avoided. Do not move vehicle unless absolutely nec‐
essary.

1.3 Assembly overview - turbocharger

♦ Part I ⇒ page 243
♦ Part II ⇒ page 245
♦ Part III ⇒ page 246

1.3.1 Part I

1. Turbocharger 243
 Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
4-cylinder injection engine (2.0 l engine, turbocharger) - Edition 08.2014

1 - Gasket
❑ Renew
2 - 20 Nm
❑ Renew
❑ Coat studs of exhaust
manifold with high-tem‐
perature paste.
❑ High-temperature paste
⇒ Electronic Parts
Catalogue (ETKA) .
3 - 35 Nm
4 - Seal
❑ Renew
5 - 9 Nm
6 - 23 Nm
❑ On coolant return line
only fitted with two re‐
tainers

cardiagn.com
7 - Coolant return line
❑ Gradual introduction of
coolant return lines with
one retainer
Volkswagen AG
8 - Turbocharger agen
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❑ Removing and installing
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⇒ page 247 . ho
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9 - Bracket ss c
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10 - 30 Nm
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❑ Coat bolt with high-tem‐

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⇒ Electronic Parts
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Catalogue (ETKA) .
spec
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11 - 30 Nm
❑ Coat bolt with high-temperature paste
❑ High-temperature paste ⇒ Electronic Parts Catalogue (ETKA) .
rrectness of i

12 - Bracket
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13 - 23 Nm
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14 - 30 Nm
m

❑ Do not loosen to remove turbocharger

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❑ Coat studs of exhaust manifold with high-temperature paste.

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❑ High-temperature paste ⇒ Electronic Parts Catalogue (ETKA) .

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15 - Clamping rail
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Prote AG.

244 Rep. gr.21 - Turbocharging/supercharging

 Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
4-cylinder injection engine (2.0 l engine, turbocharger) - Edition 08.2014

1.3.2 Part II

1 - Seal
❑ Renew
2 - 30 Nm
3 - Oil supply line
4 - Turbocharger
❑ Removing and installing
⇒ page 247 .
5 - 9 Nm
6 - 30 Nm
7 - Seal
❑ Renew
8 - 35 Nm
9 - Seal

cardiagn.com
❑ Renew
10 - Coolant supply line
11 - 23 Nm
12 - 35 Nm
13 - 9 Nm wage
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14 - Seal byV ua
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❑ Renew utho
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16 - Oil return line

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17 - 9 Nm
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18 - Gasket
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1. Turbocharger 245
 Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
4-cylinder injection engine (2.0 l engine, turbocharger) - Edition 08.2014

1.3.3 Part III

1 - Turbocharger
❑ Removing and installing
⇒ page 247 .
2 - Gasket
❑ Renew
3 - 9 Nm
4 - Crankcase breather line
5 - Heat shield
6 - Connecting hose
7 - Vacuum unit
❑ Removing and installing
⇒ page 256 .
❑ Adjusting ⇒ page 256 .
8 - Nozzle

cardiagn.com
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❑ Renew rise
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10 - Hose ss a ra
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11 - Hose
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13 - Charge pressure control

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14 - 8 Nm

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15 - Seal
16 - Connection rrectness of i

17 - Securing clip
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18 - 7 Nm
19 - Hose
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20 - 7 Nm
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23 - Turbocharger air recirculation valve - N249-

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❑ Note installation position ⇒ page 247

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24 - Seal
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246 Rep. gr.21 - Turbocharging/supercharging

 Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
4-cylinder injection engine (2.0 l engine, turbocharger) - Edition 08.2014

Installation position of air recirculation valve for turbocharger -

N249-
– Observe installation position -arrows-
AG. Volkswagen AG d
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1.4 Removing and installing turbocharger
hole

spec
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Special tools and workshop equipment required

t to the co
♦ Hose clip pliers - VAS 6499-

rrectness of i
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♦ Tensioning strap - T10038- ht. rig
rig ht
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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:
♦ Check air filter housing, air filter element and intake hoses
for soiling.
♦ Check complete charged air routing and charge air cooler
for foreign objects.
If foreign objects are found in the charge air system, the charg‐
ed air routing must be cleaned and the charge air cooler must
be renewed, if necessary.

1. Turbocharger 247
 Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
4-cylinder injection engine (2.0 l engine, turbocharger) - Edition 08.2014

Removing:
– Remove engine cover/air filter ⇒ page 271 and remove intake
hose ⇒ Item 11 (page 271) from turbocharger.
– Drain coolant ⇒ page 125 .
– Remove right front part of wheel housing liner.

– Pull charge air hose -arrow- off charge air cooler.

cardiagn.com
– Unscrew bolts -arrows- and remove charge air pipe.
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– Pull off connectors -1 and 2- and unclip wire.

– Unscrew bolts -arrows- and remove union from turbocharger.
rrectness of i
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248 Rep. gr.21 - Turbocharging/supercharging

 Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
4-cylinder injection engine (2.0 l engine, turbocharger) - Edition 08.2014

– Disconnect connector for Lambda probe - G39- -arrow- and

lay cable to side.
Golf, Eos:
– Remove wiper arms, plenum chamber cover and plenum bulk‐
head ⇒ Electrical system; Rep. gr. 92 ; Windscreen wiper
system; Removing and installing windscreen wiper system .
All vehicles:

– Pull connectors off ignition coils and lay wiring harness to side.

AG. Volkswagen AG d
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nl

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ab
ility
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wit
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hole

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– Disconnect coolant line to coolant expansion tank -arrow-.
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
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ion
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– Pull off coolant hoses -1- and -2-.

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– Disconnect coolant line -3-.
yi Co
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rig ht
py by
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Prote AG.

1. Turbocharger 249
 Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
4-cylinder injection engine (2.0 l engine, turbocharger) - Edition 08.2014

– Pull upper coolant hose off heat exchanger -arrows-.

– Remove heat shield and coolant pipe -arrows-.

cardiagn.com
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– Unbolt crankcase breather line with heat shield
by V from turbo‐ ua
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charger -1-. horis tee
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– Disconnect crankcase breather line
ss from cylinder head cover
-2- and remove. ce
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– Remove activated charcoal filter line to turbocharger from cyl‐ y li

erm

inder head cover -3-. ab

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– Loosen turbocharger oil supply line -4-.

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urposes, in part or in wh

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rrectne

– Remove the two upper securing nuts for front exhaust pipe/
turbocharger.
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250 Rep. gr.21 - Turbocharging/supercharging

 Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
AG. Volkswagen AG d
4-cylinder sw agen
injection engine (2.0 l oengine,
es n turbocharger) - Edition 08.2014
olk o
t gu
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– Unbolt heat shield for right-hand
ho
ris
drive shaft -arrows-. eo
aut ra
– Remove right drive shaft
ss ⇒ Running gear, axles, steering; c

ce
e
Rep. gr. 40 ; Removing and installing drive shafts .

nl

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es, in part or in w

t to the co
rrectness of i
– Remove the two lower securing nuts for front exhaust pipe/
l purpos

turbocharger.

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mercia

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– Unbolt bracket for exhaust system -arrows-. Prote AG.

– Separate exhaust system at clamp -arrows-.

– Pull front exhaust pipe off turbocharger and slightly push to
rear.

Note

The catalytic converter is not removed and the Lambda probe

connector is not separated.

1. Turbocharger 251
 Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
4-cylinder injection engine (2.0 l engine, turbocharger) - Edition 08.2014

– Unbolt oil supply line and coolant supply line from turbocharg‐
er -arrows-.

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agen oes
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– Remove oil return line -arrows- at turbocharger.
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– Remove bolts -1- and -2- and remove support for turbocharg‐
er.
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The following procedure is necessary to provide more space be‐

for

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tween the cylinder head and bulkhead.

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– Remove bolts -2 and 3-.

252 Rep. gr.21 - Turbocharging/supercharging

 Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
4-cylinder injection engine (2.0 l engine, turbocharger) - Edition 08.2014

– Pull engine approx. 20 mm to rear using tensioning strap -

T10038- .

– Disconnect coolant pipe -arrow-. AG. Volkswagen AG d

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♦ The clamping strip nuts need not be loosened. s

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Prote AG.

1. Turbocharger 253
 Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
4-cylinder injection engine (2.0 l engine, turbocharger) - Edition 08.2014

– Unscrew bolt -1- for coolant pipe and remove Aupper

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– Remove turbocharger/exhaust
or
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When a mechanical fault is found on the turbocharger, e.g. a

wit
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the turbocharger. To prevent this from causing further damage,
hole

spec
perform the following repairs:
es, in part or in w

t to the co
♦ Check air filter housing, air filter element and intake hoses
for soiling.
♦ Check complete charged air routing and charge air cooler

rrectness of i
for foreign objects.
l purpos

If foreign objects are found in the charge air system, the charg‐
ed air routing must be cleaned and the charge air cooler must

nf
ercia

be renewed, if necessary.

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Installation is carried out in the reverse order. When installing,

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♦ Fitting hose connections with plug-in connectors ⇒ page 242
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♦ Renew seals, gaskets and self-locking nuts.
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ht. rig
♦ Fill turbocharger with engine oil at oil supply line connection. rig ht
py by
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♦ The coolant return line ⇒ Item 7 (page 244) must be installed cted agen
Prote AG.
together with the turbocharger.
♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly. The oil seals and seal‐
ing surfaces must be oiled lightly only for plug-in connector
⇒ page 242 .
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ EKTA (Electronic Parts Cata‐
logue) .
♦ After installing turbocharger, run engine for about 1 minute at
idling speed to ensure that oil is supplied to turbocharger.
Specified torques ⇒ page 243 .
Component Nm
Pendulum support to gearbox ⇒ page 13
Exhaust manifold/turbocharger to cylinder 201)
head
Oil supply line to turbocharger 30
Oil return line to turbocharger 9
Coolant supply line to turbocharger 35
Turbocharger bracket to cylinder block 302)
Turbocharger bracket to turbocharger 302)
Air intake pipe (right side) to sump 10
1) Renew nuts.
2)Use high-temperature paste ⇒ ETKA (Electronic Parts Cata‐
logue) .

254 Rep. gr.21 - Turbocharging/supercharging

 Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
4-cylinder injection engine (2.0 l engine, turbocharger) - Edition 08.2014

1.5 Checking vacuum unit for turbocharger

Special tools and workshop equipment required
♦ Hand vacuum pump - VAS 6213-

Test prerequisite:
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♦ Hose from turbocharger via charge pressure control solenoid yV
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♦ Charge pressure control solenoid valve - N75- OK.
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Procedure:

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– Remove engine cover/air filter ⇒ page 271 .

ility
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wit
– Connect hand-operated vacuum pump - VAS 6213- to vacuum
, is n

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unit -arrow-.
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spec
es, in part or in w

t to the co
rrectness of i
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mercia

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ion
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– Move slide ring -1- on hand vacuum pump - VAS 6213- to po‐
o

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sition -B- for “pressure”.

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The pressure must not exceed 750 mbar! If the pressure is yri
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exceeded, the vacuum unit can be damaged.
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– Operate hand vacuum pump - VAS 6213- several times and

observe the linkage.
The linkage -A- should start to move at a pressure of approx.
300 mbar and be at its limit stop at a pressure of approx.
700 mbar.

1. Turbocharger 255
 Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
4-cylinder injection engine (2.0 l engine, turbocharger) - Edition 08.2014

The stroke of the rod is approx. 10 mm.

Note

If no pressure can be built-up using the hand vacuum pump - VAS

6213- or the pressure drops immediately again, check hand vac‐
uum pump - VAS 6213- and connecting hoses for leaks. If no fault
is found: renew vacuum unit ⇒ page 256 .

1.6 Removing and installing vacuum unit for

turbocharger
Removing:
– Remove turbocharger ⇒ page 247 . AG. Volkswagen AG d
agen oes
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– Detach locking plate above turbocharger
ed by linkage. ara
nte
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– Slacken lock nut -2-. aut ra
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ss
– Separate rod from turbocharger -3-.

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du

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itte

– Remove vacuum unit -1- from turbocharger -arrows-.

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ab
Installing:

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Installation is carried out in the reverse order. When installing,

h re
hole

note the following:

spec
es, in part or in w

– Adjusting turbocharger vacuum unit ⇒ page 256 .

t to the co
– Installing turbocharger ⇒ page 247 .
Specified torques
rrectness of i
l purpos

Component Nm
Vacuum unit to turbocharger 10
nform
mercia

1.7 Adjusting vacuum unit for turbocharger

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Prote AG.

256 Rep. gr.21 - Turbocharging/supercharging

 Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
4-cylinder injection engine (2.0 l engine, turbocharger) - Edition 08.2014

Special tools and workshop

equipment required
♦ Universal dial gauge brack‐
et - VW 387-
♦ Hand vacuum pump - VAS
6213- wage
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♦ Pressure regulating
ed
by valve - ara
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VAS 6342- thoris eo
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♦ Turbocharger
ss tester - c

ce
le

V.A.G 1397A-
un

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an
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itte

♦ Dial gauge - VAS 6341/1-

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♦ Extension, 30 mm - VAS
ot

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6341/3-
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hole

♦ Flat probe - VAS 6341/4-

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t to the co
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Prote AG.

Note

♦ This procedure is used to adjust the vacuum unit. When check‐

ing already adjusted vacuum units the values can differ.
♦ The vacuum unit must be adjusted only if the linkage has been
loosened.
♦ Adjustment is carried out when turbocharger is removed.

– Pull hose -arrow- from vacuum unit on turbocharger.

– Detach locking plate above turbocharger linkage.

1. Turbocharger 257
 Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
4-cylinder injection engine (2.0 l engine, turbocharger) - Edition 08.2014

– Slacken lock nut -2-.

AG. Volkswagen AG d
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urposes, in part or in wh
– Pre-adjust bypass flap -1- above rod of vacuum unit -arrow-,
so that the bypass flap can just be turned by hand.

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– Tighten lock nut hand-tight.

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– Connect up hand-operated vacuum pump - VAS 6213- , tur‐
r
fo

en
ng

bocharger tester - V.A.G 1397A- (connection II) and pressure

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control valve - VAS 6342- as shown in illustration. Cop py
t. rig
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– Close pressure control valve - VAS 6342- at lever -1-.
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cted agen
Prote AG.

– Move slide ring -1- on hand vacuum pump - VAS 6213- to po‐
sition -B- for “pressure”.
– Switch on turbocharger tester - V.A.G 1397A- and set sliding
switch to position II.

258 Rep. gr.21 - Turbocharging/supercharging

 AG. Volkswagen AG d
agen oes
olksw Eos 2006 n➤
ot g, Golf 2004 ➤ , Passat 2006 ➤
byV ua
4-cylinder
ris
ed
injection engine (2.0 l engine, turbocharger)
ran
tee - Edition 08.2014
tho
u or
a a
– Secure universal dial gauge
ss bracket - VW 387- to turbocharger c

ce
le
-arrows-.

un

pt
an
d
itte
– Secure dial gauge - VAS 6341/1- with dial gauge extension,

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ab
30 mm - VAS 6341/3- and flat pickup - VAS 6341/4- to uni‐

ility
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versal dial gauge bracket - VW 387- .

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– With pressure at 0 bar, set dial gauge - VAS 6341/1- to 1 mm
ole,

spec
preload.
urposes, in part or in wh

t to the co
– Turn dial of dial gauge - VAS 6341/1- to 0.
– Make sure that dial gauge can move freely.

rrectne
– Operate vacuum pump - VAS 6213- until turbocharger tester
- V.A.G 1397A- indicates 350 +/- 5 mbar.

ss
– The dial gauge must indicate between 4.1 mm and 4.3 mm;

o
cial p

f
otherwise, turn rod of vacuum unit until the value is indicated.

inform
mer

– Tighten lock nut hand-tight.

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– Repeat adjustment.
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The values in mm refer to the read value (includes 1 mm preten‐ C py
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– Vent system via pressure control valve - VAS 6342- so that
AG.

pressure reading drops to 0 mbar.

– Set dial gauge - VAS 6341/1- to 0.

Note

The following measurements must be performed in continuous

sequence. Do not allow the pressure to drop to 0 between meas‐
urements.

– Operate vacuum pump - VAS 6213- until turbocharger tester

- V.A.G 1397A- indicates 350 +/- 5 mbar.
– Read off and note value indicated on dial gauge - VAS
6341/1- .
– Operate vacuum pump - VAS 6213- until turbocharger tester
- V.A.G 1397A- indicates a value between 650 mbar and
700 mbar.
– Vent system via pressure control valve - VAS 6342- so that
pressure reading drops to 350 +/- 5 mbar.
– Read off and note value indicated on dial gauge - VAS
6341/1- .
– Add values 1 and 2 together and divide by 2.
– The result (mean value) should be 5 +/- 0.25 mm.
– Correct setting if the result (average) is not 5 +/- 0.25 mm,
tighten lock nut hand-tight and repeat measurement.
– If the result (mean value) is 5 +/- 0.25 mm, tighten the lock nut
to 5 Nm and secure with sealing paint.
– Secure locking plate above turbocharger linkage.

1. Turbocharger 259
 Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
4-cylinder injection engine (2.0 l engine, turbocharger) - Edition 08.2014

2 Charge air system

Assembly overview - charge air cooling, Golf ⇒ page 260 .
Assembly overview - sound amplifier; Golf ⇒ page 261
Assembly overview - charge air cooling, Eos, Passat
⇒ page 262 .
Removing and installing charge air cooler, Golf, Eos
⇒ page 262 .
Removing and installing charge air cooler (Passat) ⇒ page 264 .
Fitting hose connections with plug-in connectors ⇒ page 242
Schematic diagram of turbocharging system ⇒ page 265 .
olkswagen AG
en AG. V
Checking charge air system for leaks o⇒lkspage
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2.1 Assembly overview - charge air cooling, tho
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Assembly overview - sound amplifier ⇒ page 261 .

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1 - 5 Nm

t to the co
2 - Mounting
❑ For charge air cooler.
3 - Charge air cooler rrectness
❑ Removing and installing
o
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⇒ page 262 .
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mer

4 - Charge air pipe

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5 - 8 Nm
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6 - Charge air hose

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❑ Fitting hose connec‐

um
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tions with plug-in con‐

en
ng

t.
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nectors ⇒ page 242
Co
Cop py
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7 - Charge air pipe
rig ht
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❑ To sound amplifier Prote
cted AG.
agen

8 - Charge air hose

❑ Fitting hose connec‐
tions with plug-in con‐
nectors ⇒ page 242
9 - Hose clip
10 - Charge air hose
❑ To throttle valve module
- J338- .

260 Rep. gr.21 - Turbocharging/supercharging

 Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
4-cylinder injection engine (2.0 l engine, turbocharger) - Edition 08.2014

11 - Charge air hose

12 - Charge air pipe
13 - Charge air hose
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15 - Sound amplifier rise
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❑ Fasteners ⇒ page 261
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16 - Charge air pipe

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17 - Charge air hose

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❑ Fitting hose connections with plug-in connectors ⇒ page 242
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18 - Charge air pressure sender - G31-

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hole

spec
19 - 5 Nm
es, in part or in w

t to the co
2.2 Assembly overview - sound amplifier, Golf

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1 - Cover

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2 - 8 Nm

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3 - Plenum chamber bulkhead

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4 - Screen

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6 - Clip t. C rig
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7 - Charge air hose
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8 - 8 Nm
9 - Spacer sleeve
10 - Rubber bush
11 - Sound amplifier
❑ Before removing, re‐
move cover
⇒ Item 1 (page 261) .
12 - Bracket
❑ For sound amplifier
13 - 8 Nm

2. Charge air system 261

 Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
4-cylinder injection engine (2.0 l engine, turbocharger) - Edition 08.2014

2.3 Assembly overview - charge air cooling, Eos, Passat

1 - 5 Nm
2 - Mounting
❑ For charge air cooler.
3 - Charge air cooler
❑ Removing and installing
charge air cooler (Pas‐
sat) ⇒ page 264 .
❑ Removing and installing
charge air cooler, Eos
⇒ page 262 .
4 - Charge air pipe
5 - 8 Nm agen
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tions ⇒ page 242

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erm

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J338- .

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9 - Charge air hose

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10 - 10 Nm
urposes, in part or in wh

t to the co
11 - 5 Nm
12 - Charge air pressure send‐
er - G31-
rrectne

13 - Charge air pipe

ss

14 - Charge air hose

o
cial p

f in

❑ Note installation instruc‐

form
mer

tions ⇒ page 242

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2.4 Removing and installing charge air cool‐

en
ng

t.
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er (Golf, Eos) Cop py
ht. rig
rig ht
py by
Removing: co Vo
by lksw
cted agen
Prote AG.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation .
– Remove bumper cover ⇒ Bumpers; Rep. gr. 63 ; Removing
and installing front bumper cover .
– Drain coolant ⇒ page 125 .

262 Rep. gr.21 - Turbocharging/supercharging

 AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
orise Eos 2006 ➤ , Golf 2004 ➤ , Passat
nte 2006 ➤
h e
4-cylinder injection
aut engine (2.0 l engine, turbocharger) - Editionor08.2014 ac
ss

ce
le
– Remove right air hose -arrows-.

un

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– Remove radiator cowl ⇒ page 133 .

rm

ab
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ility
– Removing radiator ⇒ page 133 .

ot

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Pipes of condenser are bolted to right-hand side of charge air

hole

spec
cooler. To unscrew securing bolts, proceed as follows:

es, in part or in w

t to the co
rrectness of i
l purpos

– Make a paper template with the specified dimensions.

nform
mercia

a
com

tion in
r
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thi
s
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cum
fo

en
ng

t.
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cardiagn.com
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

– Fit the template on the plastic bracket at the front right so that
it rests against the edges at the top and left.
– Mark the intersection on the template -arrow- with a centre
punch.
– Drill a hole into the plastic bracket with a 5-mm drill bit.
– Drill or cut the hole to 16 mm.

– Unscrew securing bolt -arrow- for condenser pipes.

2. Charge air system 263

 Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
4-cylinder injection engine (2.0 l engine, turbocharger) - Edition 08.2014

– Unscrew bolts -1- for charge air cooler mountings.

Note
G. Volkswagen AG d
The securing bolts of the condenser are difficult to access! wWith
agen
A
oes
olks not
the aid of a second mechanic, lift the charge air cooler by out
V of the gu
ara
radiator mountings. The charge air cooler can now oris be moved
ed nte
»back and forth« to allow access to the securing
au bolts.
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wit
– Unbolt condenser from charge air cooler -arrows-.
is n

h re
ole,

– Attach condenser to lock carrier using cable ties.

spec
urposes, in part or in wh

– Take out charge air cooler from underneath.

t to the co
Installing:

rrectne
Installation is carried out in the reverse order. When installing,
note the following:

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ss
♦ Hose connections and hoses for charge air system must be

o
cial p

f
free of oil and grease before assembly. The oil seal and seal‐

inform
ing surface must be oiled lightly only for plug-in connectors
mer

⇒ page 242 .

atio
om

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2.5 Removing and installing charge air cool‐

thi
te

sd
va

er (Passat)
i

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pr

cum
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fo

en
ng

t.
Removing: Cop
yi Co
py
t. rig
– Remove noise insulation ⇒ General body repairs, exterior; gh ht
yri by
Rep. gr. 50 ; Noise insulation .
op Vo
by c lksw
cted agen
Prote AG.
– Remove bumper cover ⇒ Bumpers; Rep. gr. 63 ; Removing
and installing front bumper cover .
– Drain coolant ⇒ page 125 .
– Remove right air hose -arrows-.
– Remove radiator cowl ⇒ page 133 .
– Removing radiator ⇒ page 135 .
– Remove air deflector elements on lock carrier ⇒ Body - front;
Rep. gr. 50 ; Assembly overview - air deflector elements on
lock carrier .

264 Rep. gr.21 - Turbocharging/supercharging

 Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
4-cylinder injection engine (2.0 l engine, turbocharger) - Edition 08.2014

– Unscrew bolts -1- for charge air cooler mountings.

Note

The securing bolts of the condenser are difficult to access! With

the aid of a second mechanic, lift the charge air cooler out of the
radiator mountings. The charge air cooler can now be moved
»back and forth« to allow access to the securing bolts.

– On the right-hand side of the charge air cooler unscrew pipes

of condenser -arrow-.

AG. Volkswagen AG d
agen oes

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ara
ed
ris nte
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nl

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du

an
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– Unbolt condenser from charge air cooler -arrows-.

y li
erm

ab
ility
– Attach condenser to lock carrier using cable ties.
ot p

wit
, is n

– Take out charge air cooler from underneath.

h re
hole

spec
Installing:
es, in part or in w

t to the co
Installation is carried out in the reverse order. When installing,
note the following:
♦ Hose connections and hoses for charge air system must be rrectness of i
free of oil and grease before assembly. The oil seal and seal‐
l purpos

ing surface must be oiled lightly only for plug-in connectors

⇒ page 242 .
nform
ercia

2.6 Schematic diagram of turbocharging system

m

at
om

ion
c

in t
or

his
ate

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priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

2. Charge air system 265

 Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
4-cylinder injection engine (2.0 l engine, turbocharger) - Edition 08.2014

1 - Vacuum unit
❑ Removing and installing
⇒ page 256 . . Volkswagen AG
gen AG does
❑ Adjusting ⇒ page 256V.olkswa not
gu
y
❑ Check ⇒ page 255 ed b. ara
ris nte
tho eo
2 - Charge pressure
ss
au control ra
c
solenoid valve - N75-

ce
e
nl

pt
du

an
3 - Turbocharger air recircula‐
itte

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tion valve - N249-
erm

ab
ility
ot p

4 - Turbocharger

wit
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5 - Brake servo
hole

spec
6 - Non-return valve
es, in part or in w

t to the co
7 - Coolant connection
8 - Vacuum pump

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9 - Non-return valve
l purpos

10 - Oil filter bracket

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11 - Activated charcoal filter

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solenoid valve 1 - N80-

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12 - Dual non-return valve

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❑ Check ⇒ page 297 . thi

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13 - Charge air cooler

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f

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t.
14 - Throttle valve module -
yi Co
op
J338-
C py
t. rig
gh ht
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15 - Pressure regulating valve
op Vo
by c lksw
cted agen
Prote AG.
16 - To activated charcoal filter
17 - Air mass meter - G70-

2.7 Checking charge air system for leaks

Special tools and workshop equipment required
♦ Charge air system tester - V.A.G 1687-

♦ Adapter - V.A.G 1687/5-

– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Body - front; Noise insulation .

266 Rep. gr.21 - Turbocharging/supercharging

 Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
4-cylinder injection engine (2.0 l engine, turbocharger) - Edition 08.2014

– Release clip -A- and detach hose -B- from charge air pipe.

– Fit adapter - V.A.G 1687/5- onto charge air hose -A- and turn
adapter through approx. 90° -B-.
Prepare charge air system tester - V.A.G 1687- as follows:

cardiagn.com
– Turn pressure control valve -2- anti-clockwise onto stop.
– Close valves -3- and -4-.

Note
AG. Volkswagen AG d
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V -2- the knob must be pulledot gu
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– Connect charge air system tester - V.A.G 1687- as shown.

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, is n

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hole

spec
es, in part or in w

t to the co
rrectness of i
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nform
mercia

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or

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Prote AG.

2. Charge air system 267

 . Volkswagen AG
gen AG does
Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤ olks
wa not
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4-cylinder injection engine (2.0 l engine, turbocharger)is-e Edition 08.2014
d b ara
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– Connect compressed air hose -1- (compressed air source)
ss
a
to c
charge air system tester - V.A.G 1687- .

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le
un

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d
itte

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ab
Note

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If there is water in the sight glass, drain at water drain screw -6-.

h re
hole

spec
es, in part or in w
– Open valve -3-.

t to the co
– Adjust pressure to 0.5 bar with pressure control valve -2-.

rrectness of i
Caution

l purpos
The pressure must not exceed 0.5 bar! If the pressure is too
high this can cause damage to the engine.

nform
mercia

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tio
– Open valve -4- and wait until the test circuit is filled. If neces‐

n in
r

sary readjust pressure to 0.5 bar.

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do
– Check the charge air system for leaks by listening and touch‐
r
rp

cum
ing, with commercially available leak detector spray or using
fo

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ultrasonic tester - V.A.G 1842- .

t.
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Cop py
t. rig
gh ht
pyri by
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Note by c lksw
cted agen
Prote AG.

♦ Fitting hose connections with plug-in connectors ⇒ page 242

♦ A small amount of air escapes through the valves and enters
the engine. Therefore a holding pressure test is not possible.
♦ Using the ultrasonic tester - V.A.G 1842- ⇒ operating instruc‐
tions .
♦ Depressurise test circuit by detaching coupling from adapter -
V.A.G 1687/5- before removing adapter.
♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly.

268 Rep. gr.21 - Turbocharging/supercharging