Audi Workshop Service and Repair Manuals

Removing and installing turbocharger 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.   Note Secure the heat insulation sleeve in the original position when installing. –  Remove particulate filter → Chapter.

–  Remove air cleaner housing → Rep. gr.23.

–  Press release tabs and disconnect crankcase breather hose -1-. –  Remove bolt -2-, swivel air pipe with connection to rear and detach from turbocharger.   Note Disregard -item 3-.

–  Detach heat shield sleeve. –  Detach vacuum hose -2- from vacuum unit of turbocharger. –  Unplug electrical connector -1- at position sender for charge pressure positioner -G581-.   Note Disregard -item 3-.

–  Remove bolts -arrows-. –  Loosen hose clip -1- and detach pulsation damper -2-.

–  Unplug electrical connector -1- for exhaust gas temperature sender 1 -G235- and move electrical wiring clear.   Note Disregard -items 2, 3, 4-.

–  Remove bolts and detach exhaust gas recirculation pipes -A-.

–  Remove union nut -2-. –  Remove bolts -1, 3- and banjo bolts -4, 5- and detach support for turbocharger with oil supply line.

–  Remove bolts -arrows- and detach heat shield -1-.

–  Remove nuts -arrows- and detach turbocharger with exhaust manifold from cylinder head. Installing Installation is carried out in the reverse order; note the following: Tightening torques: l  → Chapter „Turbocharger - exploded view“. l  → Fig. „„Installing air hoses with screw-type clips““. l  → Chapter „Exhaust gas recirculation with exhaust gas recirculation 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 line. 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 cleaner housing → Rep. gr.23. –  Install particulate filter → Chapter.