Audi Workshop Service and Repair Manuals

Removing and installing turbocharger Special tools and workshop equipment required

t  Spring type clip pliers -VAS 5024 A- 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. Observe rules for cleanliness when working on turbocharger → Chapter

Engine cover panel (version 1): –  Pull dipstick -1- out of guide tube. –  Lift engine cover panel at sides -arrows 2- and pull off towards front -arrow 3-. –  Re-insert dipstick in guide tube.

Engine cover panel (version 2): –  Lift off engine cover panel (outside -1- and inside -2-) by pulling up evenly.

All vehicles (continued): –  Pull cover off air duct (release clips on sides) -arrows-.

–  Unclip air duct at the bottom by releasing clips -arrows-. –  Detach air duct (bottom) together with air hose.

–  Unplug electrical connector -1- at air mass meter -G70-. –  Detach vent hose -3- and air hose -2-. –  Unscrew bolt -4- and remove air cleaner housing.

–  Unplug electrical connector -1- at oil pressure switch -F1-. –  Remove oil pressure switch -2-. –  Detach oil supply pipe at oil filter bracket -3- and at coolant pipe -4-.

–  Disconnect hose going to vacuum unit for charge pressure control at separating point -arrow-.   Note Shown from rear with engine removed for illustration purposes.

–  Remove bolts -1- and -3-. –  Move vacuum hoses at rear intake pipe clear to one side. –  Disconnect hose -2- for crankcase breather system at air pipe. –  Release spring clip -4- with spring clip pliers -VAS 5024 A- and detach air pipe at connection for turbocharger.   Note Shown from rear with engine removed for illustration purposes.

–  Remove centre noise insulation -fasteners 1 ... 3-.

–  Remove noise insulation (right-side) -fasteners 1 ... 3-.

–  Remove bolts -1- and -2-. –  Remove air pipe (right-side) by lifting retaining clips -arrows- slightly.

–  Detach air intake hose from turbocharger by lifting retaining clip -arrow- slightly. –  Remove front exhaust pipe → Chapter.

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

–  Unscrew oil supply pipe at turbocharger and exhaust manifold -arrows-. –  Move oil supply pipe to the side.

–  Remove connecting pipe for exhaust gas recirculation -arrows-.

–  Remove heat shield from exhaust manifold -arrows-.

–  Unscrew nuts -arrows-. –  Take out exhaust manifold/turbocharger between subframe and body. Installing Installation is carried out in the reverse order; note the following:   Note t  Renew seals, gaskets 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) → Electronic parts catalogue. –  Install exhaust system and align it free of stress → Chapter. –  Adhere to the instructions for installing air pipes and hoses with plug-in connectors → Chapter. –  Install air pipes → Chapter. –  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
Exhaust manifold/turbocharger to cylinder head		25 1)
Heat shield to exhaust manifold/turbocharger		25
EGR connecting pipe to:	Change-over flap	20
	Exhaust manifold	25
Oil supply pipe to turbocharger		22
Bracket for oil supply pipe to exhaust manifold		25
Bracket for turbocharger to:	Cylinder block	40
	Turbocharger	20
Oil return pipe to cylinder block		30
Oil supply pipe to oil filter bracket		22
Oil pressure switch to oil filter bracket		20
l  1) Renew nuts.