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  Hose clip pliers -VAS 6362- 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.

–  Disengage coolant hose -1- at engine cover panel. –  Unscrew bolts -arrows- and remove engine cover panel. –  Remove catalytic converter with centre silencer → Chapter.

–  Release fasteners -arrows- and detach air duct -1-.

–  Detach vacuum hose -arrow- from air hose. –  Release hose clips -1 and 2- and remove air hose.   Note Disregard -item 3-.

–  Unscrew bolts -2- and detach retaining bracket -1-. –  Unplug electrical connector -3- at charge pressure sender -G31- / intake air temperature sender 2 -G299-. –  Release retainers -arrows- and detach air pipe first from throttle valve module -J338- and then from turbocharger. –  Move clear hoses at air pipe.

–  Unplug electrical connector -1- on turbocharger air recirculation valve -N249- and -2- on charge pressure control solenoid valve -N75-.

–  Remove bolt -4- and detach crankcase breather hose from turbocharger -arrow-.   Note Disregard -items 1, 2, 3-.

–  Clamp off coolant hoses with hose clamps -3094- as shown in illustration. –  Remove bolts -1, 3, 4, 5-.   Note Place a cloth underneath to catch escaping coolant. –  Disconnect coolant lines from turbocharger and move clear to one side.   Note Disregard -item 2-.

–  Remove banjo bolt -1- and bolts -2, 3- and detach oil supply line and retaining plate from turbocharger. –  Detach retaining plate.   Note t  Do not attempt to bend oil supply line to a different shape. t  Disregard -item 4-.

–  Remove bolts -2- for oil return pipe (top).   Note Disregard -item 1-.

–  Remove bolts -arrows- and detach heat shield.

–  Remove nuts -arrows- and detach bracket -1- and turbocharger with exhaust manifold.   Note Seal off open pipes/lines and connections on turbocharger with clean plugs or protective caps to prevent dirt from entering. Installing Installation is carried out in the reverse order; note the following: Tightening torques l  → Chapter „Turbocharger - exploded view“. l  → Chapter „Charge air cooler - exploded view“. l  → Fig. „„Turbocharger - tightening torque and sequence““.   Note t  Renew seals, gaskets, O-rings and self-locking nuts. t  Fill turbocharger with engine oil at connection for oil supply line. 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  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 air pipe → Chapter. –  Install air hose → Rep. gr.24. –  Install catalytic converter with centre silencer → Chapter. –  Install engine cover panel → Fig.. –  Check oil level → Booklet819. –  Check coolant level → Anchor.