Audi Workshop Service and Repair Manuals

Removing and installing turbocharger Special tools and workshop equipment required

t  Hose clamps up to Ø 25 mm -3094- Removing   Note All heat insulation sleeves which are removed must be fitted in the same position when installing.

–  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.

–  Unscrew bracket -2- for turbocharger. –  Unscrew oil return pipe -1- at turbocharger and move clear. –  Loosen air intake hoses -4- and -5- at turbocharger. –  Unscrew banjo bolt -3- for pressure pipe.

–  Disconnect hose -1- at vacuum unit for charge pressure regulating valve from turbocharger. –  Clamp off coolant supply hose at bottom of turbocharger using a hose clamp -3094-.

–  Release quick fasteners -arrows- and remove engine cover panel.

–  If fitted, detach cover -1- on right of engine compartment.

–  Disengage solenoid valve 1 for activated charcoal filter system -N80- at air duct. –  Remove bolts -arrows-. –  Remove air duct -2-.

–  Unplug electrical connector -3- at solenoid valve 1 for activated charcoal filter system -N80- and the electrical connector -5- at air mass meter -G70-. –  Detach hoses -1-, -4-, -6- and -7-. –  Remove fastener -2- and detach air cleaner housing.

–  Remove secondary air pipe (detach hoses -arrows- and unscrew bolts -1-).

–  Remove heat shield -3- from secondary air pipe -1- and from cylinder head cover.   Note Disregard -item 2-.

–  Unfasten sleeve on coolant return hose. –  Clamp off coolant return hose going to turbocharger using a hose clamp -3094-. –  Loosen hose clip -4- and disconnect coolant return hose from turbocharger connection. The connection remains fitted on the turbocharger.

–  Remove bolts -1- and -3- on oil supply pipe. –  Unscrew oil supply pipe -5- at turbocharger.   Note Do not bend the flexible joint (de-coupling element) in the exhaust system more than 10°; otherwise it could be damaged. –  Unscrew bolts -6- securing catalytic converter to turbocharger. –  Unscrew bolts -2- securing turbocharger to exhaust manifold. –  Move turbocharger to side, loosen retaining bracket and banjo bolt for coolant supply pipe on turbocharger. –  Detach turbocharger. Installing Installation is carried out in the reverse order; note the following:   Note t  Always renew gaskets, seals and self-locking nuts. t  Hose connections and hoses for charge air system must be free of oil and grease before assembly. t  Fit all heat insulation sleeves in the original position when installing. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. –  Perform the following operations before securing the turbocharger: –  Fit bracket of coolant supply hose loosely to vacuum unit for charge pressure regulating valve. –  Tighten banjo bolt to 35 Nm, then tighten securing bolt of bracket to 10 Nm.   Note Fill turbocharger with engine oil at connection for oil supply pipe. –  Check oil level → Chapter. –  Fill cooling system → Anchor.   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
Coolant supply pipe to turbocharger		35
Coolant supply pipe bracket to turbocharger		10
Turbocharger to exhaust manifold		35 → Remark → Remark
Catalytic converter to turbocharger		30
Oil return pipe to turbocharger		10
Oil supply pipe to turbocharger		23
Oil supply pipe bracket to cylinder head		23
Heat shield to:	Secondary air pipe	3.5
	Cylinder head	3.5
Bracket for turbocharger to:	Cylinder block	25
	Turbocharger	30
Hose clips (9 mm wide)		3
Hose clips (13 mm wide)		5.5

1)  Renew bolts. 2)  Coat thread and contact surface of bolt head with high-temperature paste; → Parts catalogue