Audi Workshop Service and Repair Manuals

Removing and installing turbocharger, engines with code letters BHZ, BZC, CDLA, CDLC Special tools and workshop equipment required

t  Spring type clip pliers -VAS 5024 A-

t  Hexagon key extension, 8 mm -3247- Removing –  Detach engine cover panel with air cleaner → Rep. gr.24.

–  Remove air hose -1 and 2- using hose clip pliers -V.A.G 1921-.   WARNING Hot steam or hot coolant can escape when expansion tank is opened; cover filler cap with cloth and open carefully. –  Open filler cap on coolant expansion tank. –  Drain off coolant → Chapter. –  Use screwdriver to pry off cover caps on wiper arms and unscrew hexagon nuts. –  Pull wiper arms off wiper shafts and remove.

–  Unclip washer jets -arrow-. –  Push washer jets through assembly opening back into plenum chamber, leaving hoses connected.

–  Pull off rubber seal -1- on plenum chamber cover. –  Detach plenum chamber cover -2-. –  Detach engine wiring harness at rear plenum chamber panel.

–  Remove electrical connector -arrow- for Lambda probe -G39- and Lambda probe heater -Z19- (before catalytic converter) from bracket, unplug and move clear.

–  Remove plenum chamber intermediate plate -arrows-.

–  Unplug connectors -1- on ignition coils.   Note Shown in illustration from rear with engine removed.

–  Remove heat shield -arrows-.

–  Disconnect coolant pipe going to coolant expansion tank -arrow-.

–  Disconnect coolant hose -1-. –  Disconnect coolant hose -2-. –  Unscrew coolant line -3-.

–  Unscrew crankcase breather line with heat shield from turbocharger -1-. –  Disconnect crankcase breather line from cylinder head cover -2- and remove. –  Disconnect ACF line going to turbocharger from cylinder head cover -3-. –  Unscrew oil supply line from turbocharger -4-. –  Remove catalytic converter with front exhaust pipe → Chapter. –  Remove noise insulation → Rep. gr.50.

–  Remove noise insulation (right-side) -fasteners 1 ... 3-. –  Remove drive shaft (right-side) → Rep. gr.40.

–  Remove heat shield above drive shaft using hexagon key extension, 8 mm -3247-.

–  Detach air pipe -arrow- from charge air cooler.

–  Unbolt air pipe from turbocharger -arrows-.

–  Unscrew bolts -arrows- and remove air pipe.   Note Shown in illustration from rear with engine removed.

–  Unscrew oil supply line from turbocharger -2-.

–  Unscrew coolant supply line at turbocharger -2-.

–  Detach oil return line at turbocharger -arrows-.

–  Remove bolts -1- and -2- and remove support for turbocharger.

–  Disconnect coolant pipe -arrow-.   Note t  Shown in illustration from rear with engine removed. t  The nuts on the fastening strip (bottom) do not have to be loosened.

–  Unscrew top nuts -arrows-. –  Lift out turbocharger/exhaust manifold. Installing Installation is carried out in the reverse order; note the following: l  Tightening torques → Chapter   Note t  Renew seals, gaskets and self-locking nuts. t  Fill turbocharger with engine oil at connection for oil supply line. 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 exhaust system and align it free of stress → Chapter. –  Install drive shaft → Rep. gr.40. –  Install air pipes with plug-in connectors → Chapter. –  Fill up with coolant → Chapter. –  Check oil level → Booklet808..   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.