Audi Workshop Service and Repair Manuals

Removing and installing turbocharger, engines with code letters AXX, BPY, BWA Special tools and workshop equipment required

t  Spring type clip pliers -VAS 5024 A-

t  Hexagon key extension, 8 mm -3247-

t  Engine bung set -VAS 6122-   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 the air cleaner housing, air filter element and intake hoses for dirt and foreign particles. t  Check the entire charge air system (including the charge air cooler) for foreign matter. If foreign matter is found in the charge air system, clean all relevant ducts and hoses and renew the charge air cooler if necessary. Removing –  Detach engine cover panel with air cleaner → Rep. gr.24.   WARNING Hot steam or hot coolant can escape when expansion tank is opened; cover filler cap with cloth and open carefully. –  Open filler cap on coolant expansion tank. –  Drain off coolant → Chapter. –  Use screwdriver to pry off cover caps on wiper arms and unscrew hexagon nuts. –  Pull wiper arms off wiper shafts and remove.

–  Unclip washer jets -arrow-. –  Push washer jets through assembly opening back into plenum chamber, leaving hoses connected.

–  Pull off rubber seal -1- on plenum chamber cover. –  Detach plenum chamber cover -2-. –  Detach engine wiring harness at rear plenum chamber panel.

–  Remove electrical connector -arrow- for Lambda probe -G39- and Lambda probe heater -Z19- (before catalytic converter) from bracket, unplug and move clear.

–  Remove plenum chamber intermediate plate -arrows-.

–  Unplug connectors -1- on ignition coils.   Note Shown in illustration from rear with engine removed.

–  Remove heat shield -arrows-.

–  Disconnect coolant pipe going to coolant expansion tank -arrow-.

–  Disconnect coolant hose -1-. –  Disconnect coolant hose -2-. –  Unscrew coolant line -3-.

–  Unscrew crankcase breather line with heat shield from turbocharger -1-. –  Disconnect crankcase breather line from cylinder head cover -2- and remove. –  Disconnect ACF line going to turbocharger from cylinder head cover -3-. –  Unscrew oil supply line from turbocharger -4-. –  Remove catalytic converter together with front exhaust pipe. Engines with code letters AXX, BPY, BWA → Chapter. Engines with code letters BHZ, BZC, CDLA, CDLC → Chapter –  Remove noise insulation → Rep. gr.50.

–  Remove noise insulation (right-side) -fasteners 1 ... 3-. –  Remove drive shaft (right-side) → Rep. gr.40.

Four-wheel drive vehicles –  Remove heat shield above drive shaft using hexagon key extension, 8 mm -3247-.

Front-wheel drive vehicles –  Unbolt heat shield for drive shaft (right-side) -arrows-.

All models: –  Detach air pipe -arrow- from charge air cooler.

–  Unbolt air pipe from turbocharger -arrows-. –  Detach electrical connectors -1 and 2- and move wire clear.

–  Unscrew bolts -arrows- and remove air pipe.   Note Shown in illustration from rear with engine removed.

–  Unscrew oil supply line from turbocharger -2-.

–  Unscrew coolant supply line at turbocharger -2-.

–  Detach oil return line at turbocharger -arrows-.

–  Remove bolts -1- and -2- and remove support for turbocharger.

–  Disconnect coolant pipe -arrow-.   Note t  Shown in illustration from rear with engine removed. t  Nuts of fastening strip do not have to be unscrewed.

–  Remove coolant pipe bolt -1- (if fitted) from cylinder head. –  Unscrew top nuts -arrows-. –  Lift out turbocharger/exhaust manifold. Installing Installation is carried out in the reverse order; note the following: l  Tightening torques → Chapter   Note t  Renew seals, gaskets 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) → Parts catalogue. –  Install exhaust system and align it free of stress → Chapter. –  Install drive shaft → Rep. gr.40. –  Install air pipes with plug-in connectors → Chapter. –  Fill up with coolant → Chapter. –  Check oil level → Booklet808.   Note After installing turbocharger, allow engine to idle for approx. 1 minute and do not rev up immediately to ensure turbocharger is supplied with oil.