Audi Workshop Service and Repair Manuals

Removing and installing turbocharger Special tools and workshop equipment required

t  Hose clamps for hoses up to 25 mm -3094-

t  Engine bung set -VAS 6122-

t  Puller -T10112- Removing   Caution If the turbocharger has suffered mechanical damage (e.g. damaged compressor wheel), it is not sufficient merely to fit a new turbocharger. The following work must be performed in order to avoid further damage: t  Check air cleaner housing, air filter element and air hoses for dirt and foreign particles. t  Check the entire charge air system (including the charge air cooler) for foreign matter. t  If foreign matter is found in the charge air system, clean all relevant ducts and hoses and renew charge air cooler if necessary. –  Remove catalytic converter → Chapter.

–  Disconnect crankcase breather hose -1-. –  Release hose clip -2- and detach air hose. –  Unplug electrical connector -3-.

–  Remove bolts -1- and detach retaining bracket. –  Unplug electrical connector -2- on charge pressure sender -G31-/intake air temperature sender 2 -G299- and move clear electrical wiring. –  Release retainers -arrows- and detach air pipe -3- first from throttle valve module -J338- and then from turbocharger. –  Fold open cover -4- and remove bolt behind it.

–  Pull off spark plug connectors -arrows- using puller -T10112- and move ignition cables back towards rear.

–  Remove banjo bolt -2-. –  Remove bolt -3- and detach oil supply pipe.   Note Disregard -item 1-.

–  Clamp off coolant hoses using hose clamps up to 25 mm -3094-, release hose clips -arrows- and disconnect hoses. –  Unscrew bolts -1 and 2- and detach coolant pipes.

–  Unscrew bolt -1- and pull oil return pipe -2- out of turbocharger. –  Unscrew bolt for heat shield -3- and detach heat shield.

–  Slacken nuts in the sequence: -H … A-. –  Remove nuts and detach turbocharger with exhaust manifold. –  Seal off open pipes/lines and connections with clean plugs from engine bung set -VAS 6122-. Installing Installation is carried out in the reverse order; note the following: Tightening torques l  → Chapter „Oil filter bracket and engine oil cooler - exploded view“. l  → Chapter „Turbocharger - exploded view“. l  → Chapter „Charge air cooler - exploded view“.   Note t  Renew seals, gaskets, O-rings and self-locking nuts. t  Fill turbocharger with engine oil at connection for oil supply pipe. t  Hose connections and hoses for charge air system must be free of oil and grease before assembly. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue. t  To ensure that the air hoses can be properly secured at their connections, spray rust remover onto the worm thread of used hose clips before installing. t  After installing the turbocharger, allow the engine to idle for approx. 1 minute without pressing the accelerator to ensure that the turbocharger is supplied with oil. –  Install catalytic converter → Chapter. –  Install spark plug connectors → Rep. gr.28. –  Check oil level → Booklet808. –  Check coolant level → Anchor.