Audi Workshop Service and Repair Manuals

Removing and installing turbocharger Special tools and workshop equipment required

t  Hose clip pliers -VAS 6340- Removing –  Observe rules for cleanliness → Chapter.   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 particulate filter → Chapter.

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

–  Press release tabs and disconnect crankcase breather hose -1- from cylinder head cover. –  Move clear vacuum hoses -arrows- at air pipe. –  Loosen hose clip -2- and detach air pipe.

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

–  Unplug electrical connector -3- for exhaust gas temperature sender 1 -G235- and move electrical wiring clear.   Note Disregard -items 1, 2, 4 and 5-.

–  Remove bolts -arrows-. –  Using removal lever -80 - 200-, move clear electrical wiring and hoses at air pipe (left-side). –  Release hose clip -3- and push air pipe (left-side) from turbocharger towards the left.   Note Disregard -items 1, 2, 4 and 5-.

–  Unscrew oil supply line from connection on turbocharger. To do so, counterhold at hexagon flats with an open-end spanner and slacken union nut -3-.   Note Disregard -items 1, 2-.

–  Remove nuts -arrow- for coupling rod on anti-roll bar on both sides.

–  Unscrew nuts -arrows- for swivel joint (right-side). –  Detach swivel joint from wishbone (right-side).

–  Pivot drive shaft (right-side) towards the front. –  Tie up drive shaft to longitudinal member -arrow-.   Note Take care not to damage the surface coating of the drive shaft.

–  Unscrew nuts -1- and detach heat shield (left-side) from exhaust manifold. –  Remove nuts -2- and bolts -3-, and detach exhaust gas recirculation pipe.

–  Remove bolts -1, 2- and banjo bolt -3-. –  Detach support for turbocharger with oil return pipe.

–  Remove bolts -arrows- and detach turbocharger with exhaust manifold from cylinder head.

–  Move clear electrical wiring for exhaust gas temperature sender 1 -G235--item 1-. –  Remove bolts -arrows- and detach heat shield. –  Take out turbocharger with exhaust manifold from below, at the same time pushing engine/gearbox assembly slightly forwards. Installing Installation is carried out in the reverse order; note the following: l  Tightening torques → Chapter „Turbocharger - 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  Hose connections and air pipes and hoses 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. t  Fit heat insulation sleeves in the original positions when installing. –  Install exhaust system and align free of stress → Chapter. –  Install wishbone and coupling rod → Rep. gr.40. –  Install air pipe (left-side) → Chapter. –  Install air cleaner housing → Rep. gr.23. –  Install particulate filter → Chapter. –  Check oil level → Booklet808.