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21 – Turbocharging/supercharging
1 Charge air system with turbocharger
Safety precautions ⇒ page 230 .
Rules for cleanliness ⇒ page 230 .
Hose connections with push-on connectors ⇒ page 231
Assembly overview - turbocharger with attachments
⇒ page 232
Assembly overview - parts of charge air cooling ⇒ page 237 .
Checking charge air system for leaks ⇒ page 238
1.1 Safety precautions
WARNING
When doing any repair work, especially in the engine compart‐
ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant, refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ Ensure that there is sufficient clearance to all moving or
hot components.
Observe following if test and measuring instruments are required
during a road test:
♦ Test and measuring instruments must always be secured to
rear seat and operated by a second person from this location.
If test and measuring instruments are operated from front pas‐
senger seat and the vehicle is involved in an accident, there is a
possibility that the person sitting in this seat may receive serious
injuries when the airbag is triggered.
1.2 Rules for cleanliness
When working on the turbocharger, pay careful attention to the
following rules for cleanliness:
♦ Thoroughly clean all unions and surrounding areas before dis‐
connecting.
♦ Place removed parts on a clean surface and cover. Use only
lint-free cloths.
♦ 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.).
♦ Existing transport and protective packaging and sealing caps
must only be removed immediately prior to installation.
♦ When making repairs, remove oil from connection and hose
ends.
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011
230 Rep. gr.21 - Turbocharging/supercharging
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