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

–  Pull off engine cover panel -arrows-.   WARNING Hot steam/hot coolant can escape - risk of scalding. t  The cooling system is under pressure when the engine is hot. t  To allow pressure to dissipate, cover filler cap on coolant expansion tank with cloth and open carefully. –  Open filler cap on coolant expansion tank. –  Drain off coolant → Chapter.

–  Remove heat shield -arrows-.

–  Unscrew crankcase breather line from turbocharger -1-. –  Disconnect crankcase breather line from cylinder head cover -2- and remove. –  Disconnect breather hose (leading to turbocharger) from cylinder head cover -3-. –  Unscrew oil supply pipe from turbocharger -4-. –  Remove catalytic converter → Chapter.

–  Unbolt coolant supply line at turbocharger -arrow-.

–  Vehicles with auxiliary heater: remove bolts -arrows- securing exhaust pipe for auxiliary/additional heater to noise insulation.

–  Release quick-release fasteners -1- and -2- and take off front noise insulation. –  If fitted, open quick-release fasteners -3- and remove rear noise insulation.

–  Detach air intake hose -1- going to turbocharger (bottom right). –  Detach air intake hose (leading to charge air cooler) at lock carrier -2-.

–  Detach electrical connectors -1 and 2- and move wire clear.

–  Unscrew oil supply pipe for turbocharger at cylinder block -1-. –  Unscrew bolt -2- of support for turbocharger.

–  Remove oil supply pipe for turbocharger -arrows-.

–  Remove oil return pipe -arrows- at turbocharger.

–  Loosen bolt -arrow- of support for turbocharger 2 turns.

–  Disconnect coolant pipe -arrow-.

–  Unbolt coolant pipe -1- (if fitted) from cylinder head.   Note 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 „Turbocharger - exploded view“   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) → Parts catalogue. –  Install exhaust system and align it free of stress → Chapter. –  Fill up with coolant → Chapter. –  Check oil level → Booklet803.   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.