Audi Workshop Service and Repair Manuals

Removing and installing turbocharger - engine codes BPW, BRB, BRC 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 exhaust pipe: vehicles with manual gearbox → Chapter; vehicles with multitronic gearbox → Chapter. –  Remove particulate filter → Chapter.

–  Detach air intake hose from turbocharger by lifting retaining clip -arrow- slightly.

Vehicles with multitronic gearbox: –  Remove oil return pipe at turbocharger -arrow-.

–  Remove bracket for turbocharger -arrows-. –  Release quick-fasteners -1- and -2- and take off noise insulation panels.

Vehicles with manual gearbox 01E, 01X: –  Remove bolts -1- and -2- and detach support for turbocharger.   Note Place a cloth underneath to catch any escaping oil. –  Remove oil return pipe -3- at cylinder block.

All vehicles: –  Unscrew nuts -2- and -3- (accessible from below) connecting turbocharger to exhaust manifold.   Note Disregard -item 1-.

–  Detach crankcase breather hose -2- from cylinder head cover. –  Remove bolts -3- and -4-. –  Detach hose -1- between charge air cooler and turbocharger. –  Remove intake manifold together with exhaust gas recirculation cooler → Rep. Gr.23.   Note It is not necessary to disconnect the coolant hoses on exhaust gas recirculation cooler.

–  Disconnect hose -arrow- from vacuum unit for charge pressure control.

–  Unscrew oil supply pipe at turbocharger and exhaust manifold -arrows-.

–  Unscrew securing nut accessible from above -1- connecting turbocharger to exhaust manifold and remove turbocharger.   Note Disregard items marked -2- and -3-. –  Detach turbocharger. 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) → Electronic parts catalogue. t  To ensure that the charge air hoses can be properly secured at their connections, spray rust remover onto the worm thread of used hose clips before installing.

–  When installing air intake hoses with plug-in connectors, ensure that the securing clip -arrow- engages audibly on the retaining lug -A-. –  Install exhaust gas recirculation cooler → Rep. Gr.23. –  Install particulate filter → Chapter. –  Install front exhaust pipe: vehicles with manual gearbox → Chapter; vehicles with multitronic gearbox → Chapter. –  Align exhaust system so it is free of stress → Chapter. –  Check oil level → Booklet803 or → Booklet805.   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)2)
Oil supply pipe to turbocharger		22
Bracket for turbocharger to turbocharger (vehicles with manual gearbox 012, 01W, 0A9 and multitronic gearbox)		20
Bracket for turbocharger to engine support (vehicles with manual gearbox 012, 01W, 0A9 and multitronic gearbox)		25
Oil return pipe to turbocharger (vehicles with manual gearbox 012, 01W, 0A9 and multitronic gearbox)		15
Support for turbocharger to turbocharger (vehicles with manual gearbox 01E, 01X)		20
Support for turbocharger to cylinder block (vehicles with manual gearbox 01E, 01X)		30
Oil return pipe to cylinder block (vehicles with manual gearbox 01E, 01X)		40
Oil supply pipe to bracket		10
Air intake hose to turbocharger		8
Hose clips	Width 9 mm	3
	Width 13 mm	5.5
l  1) Renew nuts. l  2) Coat threads and contact surface with high-temperature paste; for high-temperature paste refer to → Electronic parts catalogue.