Passat 1997 , Passat Variant 1997

Engine Mechanical, Fuel Injection and Ignition - Edition 08.2011

Removal and Installation

5.1 Turbocharger, page 183

5.1

Turbocharger

Special tools and workshop equipment required

Hose Clamps Up to 25 mm Dia. -3094Removing
Note

During installation, install all heat insulation sleeves at the same

locations.
Remove the noise insulation by loosening the fasteners
-arrows-.

Loosen the bolts on the A/C compressor ribbed belt tensioning

roller -arrows-, release the tension on the ribbed belt and re
move it.
WARNING

Do not open the air conditioning refrigerant circuit.

Remove the A/C compressor from the bracket and secure it
on the body with wire.

5. Removal and Installation

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Passat 1997 , Passat Variant 1997

Engine Mechanical, Fuel Injection and Ignition - Edition 08.2011
Remove the turbocharger bracket -2-.
Remove the oil return line -1- from the turbocharger and move
it to the side.
Remove the air guide hoses -4 and 5- from the turbocharger.
Remove the pressure line banjo bolt -3-.

Remove the hose -1- from the charge pressure regulator valve
vacuum diaphragm on the turbocharger.
Clamp off the coolant supply hose on the bottom of the turbo
charger with the -3094- .

Loosen the quick-release fasteners and remove the engine

cover -arrows-.

Remove the air filter cover -arrow-.

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Rep. Gr.21 - Turbocharger, Supercharger

Passat 1997 , Passat Variant 1997

Engine Mechanical, Fuel Injection and Ignition - Edition 08.2011
Remove the bolts -arrows-.
Remove the air ducts -1 and 2-.

Disconnect the electrical connectors:

1-

At evaporative emission (EVAP) canister purge regulator

valve -N80-

2-

At mass air flow (MAF) sensor -G70-

3-

On the wastegate bypass regulator valve -N75-

Remove the EVAP canister purge regulator valve 1 from the

air filter housing.
Remove the hose connections, free up the wires and remove
the air filter housing -arrows-.

Remove the hoses -arrows- and bolts -1- and remove the sec
ondary air injection pipe.

5. Removal and Installation

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Passat 1997 , Passat Variant 1997

Engine Mechanical, Fuel Injection and Ignition - Edition 08.2011
Remove the heat shield -3- from the secondary air injection
pipe -1- and from the cylinder head.
Note

Ignore -2-.

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Rep. Gr.21 - Turbocharger, Supercharger

Passat 1997 , Passat Variant 1997

Engine Mechanical, Fuel Injection and Ignition - Edition 08.2011
Attach the boot to the coolant return hose.
Clamp off the coolant return hose to the turbocharger with the
-3094- .
Remove the coolant return hose -4- from the line to the turbo
charger. The line remains installed on the turbocharger.
Remove the oil supply line bolts -1 and 3-.
Disconnect the oil supply line -5- from the turbocharger.
Note

Do not bend the exhaust system flex joint more than 10 or it could
be damaged.
Remove the bolts -6- connecting the catalytic converter to the
turbocharger.
Remove the bolts -2- connecting the turbocharger to the ex
haust manifold.
Tilt the turbocharger to the side and loosen the angled bracket
and banjo bolt for the coolant supply line on the turbocharger.
Remove the turbocharger.
Installing
Installation is done is reverse order, observe the following:
Note
Replace gaskets, seals and self-locking nuts.
Hose connections and charge air system hoses must be free

of oil and grease before installing.

During installation, install all heat insulation sleeves at the

same locations.

Secure all hose connections using hose clamps appropriate

for the model type, refer to the electronic parts catalog ETKA.

Perform the following steps before securing the turbocharger:

Secure the coolant supply line loosely with the bracket to the
pressure regulator valve vacuum diaphragm.
First tighten the banjo bolt and then the coolant supply line
bracket bolt.
Note

Fill the turbocharger with engine oil at the oil supply line connec
tion.
Check oil level. Refer to 1.1 Engine Oil, page 78
Fill the coolant. Refer to
1.2 Cooling System, Draining and Filling, page 92 .

5. Removal and Installation

187

Passat 1997 , Passat Variant 1997

Engine Mechanical, Fuel Injection and Ignition - Edition 08.2011
Note

After installing the turbocharger, let the engine run at idle for ap
proximately 1 minute without pressing the accelerator pedal to
make sure the turbocharger is supplied with oil.
Tightening Specifications
Component

Nm

Coolant supply line to turbocharger

Coolant supply line bracket to turbocharger
Turbocharger on exhaust manifold

35
10

Catalytic converter to turbocharger

30 2)
10
23
23

Oil return line to exhaust turbocharger

Oil supply line to exhaust turbocharger
Oil supply line to cylinder head
Heat shield to
Secondary Air Injection
(AIR) pipe
Cylinder head
Turbocharger
Cylinder block
bracket to
Turbocharger
Hose clamps for coolant hoses
Air guide hose clamps
1) Replace bolts.

2)

35 1)2)

3,5
3,5
25
30
2
3,5

Coat the thread and head contact surfaces with hot bolt
paste; hot bolt paste, refer to the electronic parts catalog
ETKA.

188

Rep. Gr.21 - Turbocharger, Supercharger

Passat 1997 , Passat Variant 1997

Engine Mechanical, Fuel Injection and Ignition - Edition 08.2011

Special Tools

Special tools and workshop equipment required

Spring Type Clip Pliers -VAS 5024 A-

Hand Vacuum Pump -V.A.G 1390-

Hose Clamps Up to 25 mm Dia. -3094-

Testing Unit for Turbo Charger -V.A.G 1687 Accessory Adapter -V.A.G 1687/1-

6. Special Tools
Copyright 2011 - 2013 Service Repair Solutions, Inc.

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