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 -3094-

t  Hose clip pliers -VAS 6362- Removing   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 catalytic converter with centre silencer → Chapter.

–  Remove bolts -1 and 3-. –  Release hose clip -2-, detach air pipe (top right) and remove air hose.

–  Unplug electrical connector -2-. –  Detach vacuum hoses -1-.

–  Unscrew bolts -arrows- and remove retaining plate -1-.

–  Remove bolts -arrows- and ball stud -1-.   Note Place a cloth underneath to catch escaping coolant. –  Disconnect coolant lines from turbocharger, lift clear and tie up.

–  Remove banjo bolts -arrows- on valve timing housing and turbocharger and detach oil supply line.

–  Remove bolts -arrows- and detach oil return line -1- for turbocharger.

–  Remove nuts in the sequence: -9 ... 1- and detach turbocharger with exhaust manifold.   Note Seal off open pipes/lines and connections on turbocharger with clean plugs or protective caps to prevent dirt from entering. Installing Installation is carried out in the reverse order; note the following: Tightening torques l  → Chapter „Turbocharger - exploded view“. l  → Chapter „Charge air cooler - exploded view“. l  → Fig. „„Turbocharger - tightening torque and sequence““.   Note t  Renew seals, gaskets, O-rings and self-locking nuts. t  Fill turbocharger with engine oil at connection for oil supply line. 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. –  Install air pipe (top right) → Chapter. –  Install air hoses with screw-type clips → Fig.. –  Install catalytic converter with centre silencer → Chapter. –  Check oil level → Booklet819. –  Check coolant level → Anchor.