Audi Workshop Service and Repair Manuals

Removing and installing turbocharger - vehicles with engine code letters ATL, BHC Special tools and workshop equipment required

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

t  Hose clip pliers -VAS 6340- 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 front right wheel. –  Remove catalytic converter → Chapter.

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

–  Detach vacuum hose -1- from vacuum unit for charge pressure control and move it clear. –  Unscrew bolts -2- and detach air pipe from turbocharger.   Note Air pipe remains in installation position. –  Detach air intake hose -3- from turbocharger.

–  Remove nuts -1-.   Note t  Shown in illustration with engine removed. t  The bolts -2 and 3- are removed at a later stage.

–  Remove heat shield for turbocharger -arrows-.

–  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.

–  Remove air hose -3- from intake manifold flap motor -V157- by lifting retaining clip -2- slightly. –  Disconnect vacuum hose -1- at mechanical exhaust gas recirculation valve.

–  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. –  Pull air pipe out slightly together with air mass meter -G70-.

–  Detach electrical connector -arrow- at heater element for crankcase breather -N79-. –  Remove air pipe.

–  Detach electrical connector -arrow- at intake manifold flap motor -V157-. –  Remove bolts -1 … 3- and take out intake manifold flap motor -V157-.

–  Clamp off coolant hoses going to exhaust gas recirculation cooler using hose clamps -3094-. –  Detach coolant hoses at exhaust gas recirculation cooler.

–  Remove bolts -2 and 3- and detach exhaust gas recirculation cooler.   Note Disregard -item 1-.

–  Unscrew bolts -arrows- and remove intake manifold.

–  Detach oil supply pipe -2- going to turbocharger at oil filter bracket. –  Remove bracket for oil supply pipe -3-.   Note Disregard -item 1-.

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

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

–  Remove bolts -1 and 2- and detach support for turbocharger. –  Unbolt oil supply pipe -3- at cylinder block.

–  Remove bottom nuts -arrows 2-.

–  Unscrew bolts -1- for pendulum support.   Note Disregard -items 2 and 3-.

–  Remove top nuts -arrows 1-. –  Lift out turbocharger towards left. 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 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 cylinder head		25 1)
Heat shield to turbocharger		22
Support for turbocharger to cylinder block		25
Oil return pipe to cylinder block		30
Oil supply pipe to:	Turbocharger	22
	Oil filter bracket	22
Exhaust gas recirculation cooler to:	Mechanical exhaust gas recirculation valve	22
	Intake manifold	20
	Turbocharger	22 1)
Intake manifold flap motor -V157- to mechanical exhaust gas recirculation valve		10
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.