VW 2000 TDI,1.9l turbo charger disassembly.

Volkswagen Turbocharger Unit DisAssembly

Turbocharger Removal & Installation

Basic History And Understanding Of Turbocharger Unit

Turbochargers are subject to enormous amounts of heat and friction due to the speeds at which they operate. On some models the turbine shaft can rotate at speeds up to 70,000 rpm. Most turbo's are cooled and lubricated by a oil supply line from the vehicles engine that feeds the unit a fresh stream of filtered oil. There is also a return line back to the oil pan. The oil in this feed line is the life line of the turbocharger. Its like blood is to a human being, without it, the turbo will cease to operate. This is just another example of why it is important that you change the oil at the manufacturers recommended intervals. If sludge formed in these lines and reduced the flow, the turbocharger unit would wear out very rapidly.

Important NOTE
If the turbo charger is being replaced, the oil lines going to and from it must be removed and cleaned. If cleaning the lines is not enough, then they must be replaced. Also if the turbocharger is being replaced due to excessive exhaust smoke, there may still be some oil in the exhaust system once the new turbo has been installed. You may have to drive the vehicle for a few miles before this smoke clears.

Turbocharger Removal:

1. Disconnect the negative battery cable. If equipped with an automatic transaxle, remove the starter.
2. Remove the nuts to disconnect the exhaust outlet pipe from the turbocharger outlet. If it's necessary to separate the exhaust pipe from the outlet pipe, follow the procedure is described in exhaust manifold removal for gasoline engines before removing the outlet pipe.
3. Clean the oil supply fitting on the top of the turbocharger and remove the supply line and bracket.
4. Remove the inlet air duct.
5. Under the vehicle, remove the oil return line and the turbocharger mounting bracket.
6. Still underneath, remove the turbo-to-manifold bolts and lift the turbocharger out from the top. The exhaust manifold can be removed after removing the EGR valve.

To install:

1. If removed, install the exhaust manifold with a new gasket and torque the bolts to 18 ft. lbs. (25 Nm).
2. Use a new gasket and fit the turbocharger to the manifold. Coat the bolt threads with anti-seize and torque the turbocharger bolts to 33 ft. lbs. (45 Nm) and the bracket nuts to 18 ft. lbs. (25 Nm).
3. Use a new gasket and connect the oil return line. Torque the bolts to 22 ft. lbs. (30 Nm).
4. Use a new gasket and connect the outlet pipe. Torque the nuts to 18 ft. lbs. (25 Nm).
5. Connect the oil supply line, install the EGR valve.

1. Remove or disconnect:
   
   
   Negative battery cable.
   

   Exhaust pipe from the turbocharger outlet.
   

   Oil supply line and bracket, after cleaning the oil supply fitting on the top of the turbocharger.
   

   Inlet air hose.
   

   Oil return line and the turbocharger mounting bracket.
   

   Turbo-to-manifold bolts. Lift the turbocharger out from the top.
   

To install:

1. Installation is the reverse of removal. Before installing the oil supply line, fill the connection on the turbocharger with engine oil.
2. Tighten the following:
   
   
   Turbocharger-to-exhaust manifold: 33 ft. lbs. (45 Nm)
   

   Mounting bracket nuts: 18 ft. lbs. (25 Nm)
   

   Turbocharger outlet nuts: 18 ft. lbs. (25 Nm)
   

   Oil return line: 22 ft. lbs. (30 Nm)
   
   
   






Fig. Exploded view of the intake and exhaust manifold, turbocharger and related components-1.9L (AHH) engine






Fig. Exploded view of the intake and exhaust manifold, turbocharger and related components-1.9L (AAA) engine






Fig. Exploded view of the intake and exhaust manifold, turbocharger and related components-1.9L (ALH) engine

VW 2000 TDI,1.9l timing belt and cam setting.

How To Set Timing Belt And Cam Setting On Volkswagen

Removing old timing belt  and setting new timing belt

1.9L VW Diesel Engine

Tools required:

A flat bar, VW tool 2065A is used to secure the camshaft in position. 

A pin, VW tool 2064 is used to fix the pump position while the timing belt is removed. 

IMP NOTE: The camshaft and pump work against spring pressure and will move out of position when the timing belt is removed. It is not difficult to find substitutes but do not remove the timing belt without these tools.

WARNING

Do not turn the engine or camshaft with the timing belt removed. The pistons will contact the valves and cause internal engine damage.

1. Disconnect the negative battery cable and remove the accessory drive belts, crankshaft pulley and the timing belt cover(s). 
2. Remove the camshaft cover and rubber plug at the back end of the camshaft.
3. Temporarily reinstall the crankshaft pulley bolt and turn the crankshaft to Top Dead Center (TDC) of No. 1 piston. The mark on the camshaft sprocket should be aligned with the mark on the inner timing belt cover or the edge of the cylinder head.Make sure you dont clean or rub off the alignment marks.
4. With the engine at TDC, insert the bar into the slot at the back of the camshaft. The bar rests on the cylinder head to will hold the camshaft in position.
5. Insert the pin into the injection pump drive sprocket to hold the pump in position.
6. Loosen the locknut on the tensioner pulley and turn the tensioner counterclockwise to relieve the tension on the timing belt. Slide the timing belt from the sprockets.
   
   
   

   
   

   Fig. Use the VW tool to lock the camshaft at TDC for timing belt replacement-Volkswagen 1.9L Diesel engines
   
   
   
   

   
   

   Fig. Locking the injection pump with the VW tool as shown-Volkswagen 1.9L Diesel engines

Installing New Timing belt For VW 1.9L Engine:

1. Install the new timing belt and adjust the tension so the belt can be twisted 45 degrees at the halfway point between the camshaft and pump sprockets. Tighten the tensioner nut to 33 ft. lbs. (45 Nm).
2. Remove the holding tools.
3. Turn the engine 2 full revolutions to return to TDC for the No. 1 cylinder. Recheck belt tension and timing mark alignment, readjust as required.
4. Install the belt cover and accessory drive belts.

This details Will Help.

Thanks.