Audi Workshop Service and Repair Manuals

Removing and installing turbocharger Special tools and workshop equipment required

t  Hose clip pliers -VAS 6340- Removing   Note Secure the heat insulation sleeve in the original position when installing. –  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-. –  Remove bolt -2-, swivel air pipe with connection to rear and detach from turbocharger.

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

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

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

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

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

–  Remove bolts -arrows- and detach heat shield.

–  Remove nuts -arrows- and detach turbocharger with exhaust manifold from cylinder head. 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  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 air hoses with screw-type clips → Fig.. –  Install exhaust gas recirculation pipes → Chapter. –  Connect vacuum hoses → Chapter. –  Electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations. –  Install air cleaner housing → Rep. gr.23. –  Install particulate filter → Chapter.