Audi Workshop Service and Repair Manuals

Removing and installing turbocharger - vehicles with engine code letters AMF Special tools and workshop equipment required

t  Hose clip pliers -V.A.G 1921- 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 intake 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 bonnet → Chapter. –  If fitted, unclip bracket -1-. –  Take off engine cover panel -arrows-. –  Remove noise insulation beneath cover.

–  Lever off caps -3 and 4- on two-piece windscreen wiper arm with a screwdriver. –  Slacken nuts on two-piece windscreen wiper arm a few turns. –  Release arms -1 and 2- one after the other by tilting them slightly on the wiper shafts. –  Remove nuts completely and take off two-piece windscreen wiper arm.   Note Use puller (commercially available) to remove wiper arm if necessary.

–  Disconnect washer fluid hose -3-. –  If fitted, unplug electrical connectors -4 and 5- for heated washer jets. –  Open hose clip -6- using hose clip pliers -V.A.G 1921- and detach water drain hose from cowl panel grille. –  Pull off rubber seal -1- on cowl panel grille. –  Disconnect cowl panel grille -2-.

–  Unscrew nuts and bolts -arrows-. –  Pull fresh air duct forwards and remove by turning it to right side of vehicle.

–  Detach air hose -2- at mechanical exhaust recirculation valve. –  Disconnect vacuum hose -3- at mechanical exhaust gas recirculation valve. –  Disconnect vacuum hose -4- from vacuum unit for intake manifold flap.   Note Disregard -item 1-.

–  Remove air intake hose -2- from charge air cooler.   Note Disregard -item 1-.

–  Detach air intake hose -1- at air mass meter -G70-. –  Unplug electrical connector -3- at air mass meter -G70-. –  Remove nut -2-. –  Disconnect crankcase breather hose -4- at cylinder head cover. –  Move aside fuel lines at air pipe.   Note The air pipe remains in the vehicle. –  Remove front right wheel. –  Remove catalytic converter → Chapter.

–  Unbolt heat shield for drive shaft (left-side) -arrows-.

–  Unbolt bracket for air pipe from sump -arrows-.

–  Detach air intake hose -6- from turbocharger. –  Remove oil return pipe by unscrewing nuts -2- and union nut -1-. –  Detach charge pressure control hose -5- at turbocharger and at vacuum unit for charge pressure control. –  Disconnect breather hose -4-. –  Unscrew bolts -3- and detach air pipe from turbocharger.   Note The air pipe remains in the vehicle.

–  Slacken bolt -1- approx. 3 turns. –  Unbolt oil supply pipe -3- from turbocharger and move clear to one side.   Note Disregard -item 2-.

–  Remove nut (bottom) -arrow- for turbocharger. –  Lift out air hose (previously disconnected from below) from turbocharger and pull out upwards.

–  Remove heat shield for exhaust manifold -arrows-.

–  Remove connecting pipe for exhaust gas recirculation -item 1 and 2-.

–  Unscrew bolts -arrows- and remove intake manifold.

–  Remove both bolts -arrows- for turbocharger (hold turbocharger in position). –  Place turbocharger on subframe. –  Take out turbocharger downwards. Installing Installation is carried out in the reverse order; note the following:   Note t  Renew gaskets, seals and self-locking nuts. t  Fill turbocharger with engine oil at connection for oil supply pipe. t  Charge air system must be free of leaks. 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. –  Install intake manifold → Rep. Gr.23. –  Install connecting pipe for exhaust gas recirculation (first tighten loosely and then tighten connections to specified torque). –  Install catalytic converter → Chapter. –  Install air pipes/hoses with plug-in connectors → Chapter. –  Install windscreen wiper arm → Rep. Gr.92. –  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		25 1)
Heat shield to exhaust manifold		22
Oil return pipe to:	Cylinder block	30
	Turbocharger	15
Oil supply pipe to turbocharger		22
Air pipe to:	Turbocharger	8
	Sump	8
	Body	8
Drive shaft heat shield to cylinder block		33
Engine cover panel to bracket		5.5
l  1) Renew nuts.