Audi Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ VAS 5024 A

Removing

• ‒ → Remove oil dipstick -1- from guide tube.
• ‒ Remove engine cover -arrows-.
• ‒ Reinsert dipstick in guide tube.

• ‒ → Disconnect hose -arrow- at vacuum unit for boost pressure control.

• ‒ → Disconnect hose -4- to air cleaner housing.
• ‒ Disconnect crankcase vent pipe -5- from air duct hose.
• ‒ Release spring clamp on turbocharger using VAS 5024 A.
• ‒ Set aside the vacuum hoses.
• ‒ Unscrew bolts -1- and -2- and remove air duct pipe -3-.

• ‒ → Unscrew oil feed line at oil filter bracket -arrow- and also at coolant pipe.

• ‒ → Remove air duct pipe from right longitudinal member -arrows-.

• ‒ → Remove centre and right noise -arrows-.

• ‒ → Unbolt heat shield for right drive shaft -arrows-.
• ‒ Detach right drive shaft from gearbox flange.

• ‒ → Unbolt bracket for exhaust system from assembly mounting
  -arrows-.

Note:

The isolating element in front exhaust pipe must not be deflected more than 10°to avoid damage.

• ‒ → Unscrew securing bolts -arrows- of front exhaust pipe/turbocharger.

• ‒ → Detach the exhaust system at the clamping sleeve -arrows-.
• ‒ Remove the front exhaust pipe.

• ‒ → Unscrew pendulum support from subframe -arrows A-.

• ‒ → Detach air duct hose -4-.
• ‒ Remove bolts -2- and -3- and detach bracket for turbocharger.
• ‒ Remove oil return pipe -1- at cylinder block.

• ‒ → Remove connection pipe for exhaust gas recirculation -arrows-.

• ‒ → Unscrew oil feed line from turbocharger and exhaust manifold
  -arrows-.

• ‒ → Remove heat shield from exhaust manifold -arrows-.

• ‒ → Unscrew nuts -arrows-.
• ‒ Remove packing plates.
• ‒ Remove exhaust manifold/turbocharger downwards.

Installing

Installation is carried out in the reverse order; note the following:

Notes:

• ◆ Always replace seals, gaskets and self-locking nuts.
• ◆ Note installation position of exhaust manifold/turbocharger gaskets.
• ◆ Fill the turbocharger with engine oil via the oil supply connection.
• ◆ Hose connections and hoses for charge air system must be free of oil and grease before assembly.
• ◆ Secure all hose connections with the correct hose clamps (same as original equipment):

=> Parts List

• ‒ Install exhaust system and align it stress-free => Page 26-13.
• ‒ Install right drive shaft.

=> Running Gear, FWD and 4WD; Repair group 40

• ‒ → When installing air duct pipes with connectors, ensure that the securing clip -arrow- engages audibly in the retaining lug -A-.
• ‒ Check oil level => Page 17-23.

Note:

After installing the turbocharger, run engine for approx. 1 minute at idling speed; do not rev. up immediately. This ensures the turbocharger is properly lubricated.

Tightening torques

    1)    Replace the nuts.

    2)    Stretch bolts, replace

    3)    90°corresponds to a quarter of a turn