Audi Workshop Service and Repair Manuals

Removing and installing turbocharger Special tools and workshop equipment required

t  Hose clamps for hoses up to 25 mm Ø -3094-

Removing   Note Fit all heat insulation sleeves in the original position when installing. –  Release fasteners -arrows- and remove noise insulation.

–  Loosen securing bolts on tensioning roller for poly V-belt for A/C compressor -arrows-, slacken belt and remove.   WARNING The air conditioner refrigerant circuit must not be opened. –  Detach air conditioner compressor from bracket and secure to body with wire.

–  Remove bracket -2- for turbocharger. –  Unbolt oil return pipe -1- from turbocharger and move clear to one side. –  Detach air hoses -4 and 5- from turbocharger. –  Remove banjo bolt -3- for pressure pipe.

–  Disconnect hose -1- at vacuum unit for charge pressure regulating valve on turbocharger. –  Clamp off coolant supply hose at bottom of turbocharger using a hose clamp -3094-.

–  Release quick-release fasteners and remove engine cover panel -arrows-.

–  Detach air cleaner cover -arrow-.

–  Remove bolts -arrows-. –  Remove air duct -1 and 2-.

–  Unplug electrical connectors: 1 -  On activated charcoal filter solenoid valve 1 -N80- 2 -  On air mass meter -G70- 3 -  On solenoid valve for charge pressure control -N75- –  Detach solenoid valve 1 for activated charcoal filter -N80- from air cleaner housing. –  Detach hose connections, move electrical wiring clear and remove air filter housing -arrows-.

–  Remove secondary air pipe (detach hoses -arrows- and unscrew bolts -1-).

–  Remove heat shield -3- from secondary air pipe -1- and from cylinder head.   Note Disregard -item 2-.

–  Unfasten sleeve on coolant return hose. –  Clamp off coolant return hose to turbocharger using a hose clamp -3094-. –  Detach coolant return hose -4- from pipe going to turbocharger; the pipe remains fitted on the turbocharger. –  Remove bolts -1 and 3- for oil supply pipe. –  Remove oil supply pipe -5- from turbocharger.   Note Do not bend the flexible joint (de-coupling element) in the exhaust system more than 10°, otherwise it could be damaged. –  Remove bolts -6- securing catalytic converter to turbocharger. –  Remove bolts -2- securing turbocharger to exhaust manifold. –  Move turbocharger to side, loosen retaining bracket and banjo bolt for coolant supply pipe on turbocharger. –  Remove turbocharger. Installing Installation is carried out in the reverse order; note the following:   Note t  Renew seals, gaskets and self-locking nuts. t  Hose connections and hoses for charge air system must be free of oil and grease before assembly. t  Fit all heat insulation sleeves in the original position when installing. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. Perform the following operations before securing the turbocharger: –  Fit coolant supply pipe together with bracket loosely at vacuum unit for charge pressure regulating valve. –  First tighten banjo bolt and then bolt securing bracket for coolant supply pipe.   Note Fill turbocharger with engine oil at connection for oil supply pipe. –  Check oil level → Chapter. –  Fill up with coolant → Anchor.   Note 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. Tightening torques

Component		Nm
Coolant supply pipe to turbocharger		35
Bracket for coolant supply pipe to turbocharger		10
Turbocharger to exhaust manifold		35 1)2)
Catalytic converter to turbocharger		30
Oil return pipe to turbocharger		10
Oil supply pipe to turbocharger		23
Oil supply pipe to cylinder head		23
Heat shield to:	Secondary air pipe	3.5
	Cylinder head	3.5
Bracket for turbocharger to:	Cylinder block	25
	Turbocharger	30
Hose clips for coolant hoses		2
Hose clips for air hoses		3.5
l  1) Renew bolts. l  2) Coat threads and contact surface of bolt heads with high-temperature paste; for high-temperature paste refer to → Parts catalogue.