Audi Workshop Service and Repair Manuals

Removing and installing turbocharger (left-side) Special tools and workshop equipment required

t  Used oil collection and extraction unit -V.A.G 1782-

Removing   Note t  All heat insulation sleeves which are removed must be fitted in the same position when installing. t  All cable ties which are released or cut open when removing must be fitted in the same position when installing. –  Remove noise insulation -arrows-. –  Place used oil collection and extraction unit -V.A.G 1782- under engine. –  Drain off engine oil. –  Remove engine → Chapter. –  Leave engine on scissor-type assembly platform -VAS 6131- with gearbox attached.

–  Unscrew bolts -1- and -2- for gearbox mounting (left and right).

–  Screw down spindles of the support elements (left and right) at subframe as far as possible. –  Remove locating lugs from spindles. –  Remove subframe to the side.

–  Take electrical connector -2- for Lambda probe 2 -G108- out of bracket (left-side) and unplug it. –  Remove heat insulation sleeve at wiring harness and move wiring clear.   Note Illustration shows electrical connectors when installed.

–  Take electrical connector -2- for Lambda probe 2 after catalytic converter -G131- out of bracket (right-side) and unplug it. –  Remove heat insulation sleeve at wiring harness and move wiring clear.   Note Illustration shows electrical connectors when installed.

–  Unscrew bolt -2- at bracket for front exhaust pipe (left-side).   Note Disregard -item 1-.

–  Slacken clip -1-. –  Unscrew bolts -2- and -3- and remove heat shield from front exhaust pipe (left-side).

–  Unscrew nuts -1 ... 4- securing front exhaust pipe to turbocharger (left-side). –  Take out front exhaust pipe with starter and main catalytic converter.

–  Unscrew sealing cap -1-. –  Loosen quick release fasteners -arrows- and remove cover panel for cylinder head cover (left-side).

–  Remove bolt -2-. –  Remove air pipe (left-side); disconnect hose connections -1- and -3- for this purpose.

–  Detach vacuum hose -1-. –  Unscrew bolt -2- and detach air pipe (left-side) from turbocharger towards the front.

–  Unscrew bolt -arrow- and detach oil return pipe from top section of sump.

–  Detach vacuum hose -1-. –  Unscrew banjo bolt -2- for pressure pipe. –  Place drip tray below turbocharger. –  Unscrew banjo bolt -3- for coolant pipe. –  Slacken hose clip -4-.

–  Unscrew exhaust gas temperature sender 1 for cylinder bank 2 -G236--arrow- from exhaust manifold flange.

–  Unscrew oil supply pipe -2- from turbocharger. –  Unscrew banjo bolt -1- for coolant pipe. –  Unscrew retaining tab -3- for coolant pipe.

–  Remove bolts -1 … 3- and take out turbocharger. Installing Installation is carried out in the reverse order; note the following:   Note t  Renew gaskets, seals, O-rings and self-locking nuts. t  Fill turbocharger with engine oil at connection for oil supply pipe. 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. t  Charge air system must be free of leaks. t  Fit all cable ties in the original positions when installing. t  Fit all heat insulation sleeves in the original position when installing. –  Install exhaust gas temperature sender 1 for bank 2 -G236- → Chapter. –  Install front exhaust pipe (left-side) with starter and main catalytic converter → Chapter. –  Install engine → Chapter. –  Fill up with engine oil and check oil level → Chapter.   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. Tightening torques

Component	Nm
Turbocharger to exhaust manifold	60 1)2)
Coolant line to turbocharger	35
Oil supply pipe to turbocharger	30
Pressure line to turbocharger	9
Oil return pipe to sump (top section)	10
Air pipe (left-side) to bracket	22
Air pipe to cylinder head cover	10
Hose clips (9 mm wide)	3
Hose clips (13 mm wide)	5.5
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.