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Removing and installing intermediate flange - engine code letters BDG, BDH > < Removing and installing turbocharger

A4 Mk2

Removing and installing intermediate flange - engine code letters AKE, AYM, BAU, BCZ, BFC
Removing and installing intermediate flange - engine code letters AKE, AYM, BAU, BCZ, BFC
Removing
  Note
All cable ties which are released or cut open when removing must be fitted in the same position when installing.
–  Remove front exhaust pipe with main catalytic converter: vehicles with front-wheel drive → Chapter, vehicles with four-wheel drive → Chapter.
–  Remove starter catalytic converter: vehicles with front-wheel drive → Chapter, vehicles with four-wheel drive → Chapter.
–  Remove turbocharger → Chapter.
–  Remove exhaust manifold together with intermediate pipe: left-side → Chapter, right-side → Chapter.
   
–  Release cable tie -1- at rear of heat shield and move wiring clear.
–  Unscrew bolts -arrows- and detach heat shield -2- from intermediate flange.
  A21-0059
–  Unscrew bolt -3- on left of mechanical exhaust gas recirculation valve.
–  Remove nuts -2- and bolts -1-.
  Note
Leave the exhaust gas recirculation pipe -4- in position.
  A21-0060
–  Remove top left securing bolt -arrow 1- on engine/gearbox flange.
–  Unscrew bolts -arrows 2-.
–  Guide out intermediate flange to rear right.
Installing
Installation is carried out in the reverse order; note the following:
  Note
t  Renew gaskets and self-locking nuts.
t  Fit all cable ties in the original positions when installing.
–  Install exhaust manifold together with intermediate pipe: left-side → Chapter, right-side → Chapter.
–  Install turbocharger → Chapter.
–  Install starter catalytic converter: vehicles with front-wheel drive → Chapter, vehicles with four-wheel drive → Chapter.
–  Install front exhaust pipe with main catalytic converter: vehicles with front-wheel drive → Chapter, vehicles with four-wheel drive → Chapter.
Tightening torques
  A21-0061
ComponentNm
Intermediate flange to cylinder block22
Support for intermediate flange to Gearbox65
Intermediate flange22
Mechanical exhaust gas recirculation valve to intake manifold22
EGR connecting pipe to:Intermediate flange22 → Note
Intake manifold (front)10

1)  Renew nuts.
   

Removing and installing intermediate flange - engine code letters BDG, BDH > < Removing and installing turbocharger