Audi Workshop Service and Repair Manuals

Removing and installing turbocharger

Removing –  Remove front exhaust pipe with catalytic converter: vehicles with front-wheel drive → Chapter, vehicles with four-wheel drive → Chapter. –  Remove air cleaner cover -2-. –  Remove air duct -1- leading to air cleaner.

–  Slacken hose clip -3-. –  Unplug electrical connector -4-. –  Pull hose -2- off air cleaner housing. –  Unscrew bolt -1- and remove air cleaner housing.

–  Disconnect hose -arrow- from vacuum unit for charge pressure control.

–  Remove air intake hose -arrows-.

–  Release hose clips -1- and push hose in direction of -arrow-. –  Unclip fuel lines from bracket at oil pipe.

–  Detach oil pipe -1- at turbocharger. –  Unscrew oil pipe at intake manifold -2-.

–  Remove turbocharger from intermediate flange -arrow- (4 nuts). –  Detach turbocharger.   Note Close off oil bore in cylinder block with clean cloths.

Installing Installation is carried out in the reverse order; note the following:   Note t  Renew gaskets, seals, O-rings and self-locking nuts. 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) → Electronic parts catalogue. t  When installing turbocharger, ensure that O-ring -arrow- for oil return is not damaged. t  Fill turbocharger with engine oil at connection for oil supply pipe. t  After installing turbocharger, allow engine to idle for approx. 1 minute and do not rev up immediately to ensure turbocharger is supplied with oil. –  Install front exhaust pipe with catalytic converter: vehicles with front-wheel drive → Chapter, vehicles with four-wheel drive → Chapter. –  Check engine oil level → Booklet802. Tightening torques

Component	Nm
Turbocharger to intermediate flange	22
Oil pipe to intake manifold	22
Oil return pipe to turbocharger	10
Oil supply pipe to turbocharger	15
Heat shield to turbocharger	10