Audi Workshop Service and Repair Manuals

Removing and installing turbocharger Special tools and workshop equipment required

t  Engine bung set -VAS 6122- Removing   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. –  Remove noise insulation → Rep. gr.66.

–  Open hose clip -arrow-, detach air hose and swivel to side.

Caution Risk of damage to flexible joints in front silencer. Do NOT bend the flexible joints in the front silencer more than 10°. –  Loosen bolted connections -arrows- and push clamp towards rear.

–  Lower front silencer slightly and tie up to cross piece -arrow-.

–  Remove nut -2- from below. –  Drain coolant → Chapter.

–  Remove bolt -1- and detach oil return line. –  Loosen bolt -2- and unscrew 2 turns.

–  Remove engine cover panel -arrows-.

–  Disconnect hose -1- from air cleaner. –  Disconnect air intake hose -2-. –  Pull air cleaner housing upwards -arrows-. –  Plug openings in turbocharger with sealing plugs from engine bung set -VAS 6122-.

–  Unplug electrical connector -1- for Lambda probe -G39- and Lambda probe heater -Z19- and move wiring clear.

–  Remove bolts -arrow- and detach crankcase breather system from turbocharger.

–  Unplug electrical connector -1- for turbocharger air recirculation valve -N249-.

–  Remove nuts -1- from above push catalytic converter towards rear.

–  Remove heat shield -arrows-.

–  Unscrew bolt -1- and remove coolant return line. –  Remove bolt -2- and detach oil supply line. –  Unplug electrical connector -3- at charge pressure positioner -V465-. –  Remove nuts -arrows-.

–  Pull turbocharger off studs in direction of -arrow-. –  Have a second mechanic hold turbocharger; remove bolt -1-, disconnect coolant supply line -2- and lift out turbocharger. Installing Installation is carried out in the reverse order; note the following: l  Tightening torques → Chapter „Turbocharger - exploded view“   Note t  Renew seals, gaskets, O-rings and self-locking nuts. t  Lubricate studs for turbocharger with high-temperature paste. For high-temperature paste refer to → Electronic parts catalogue. t  Fill turbocharger with engine oil at connection for oil supply line. 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 catalytic converter → Chapter. –  Align the exhaust system so it is free of stress → Chapter. –  Install air pipes/hoses with plug-in connectors → Chapter. –  Fill up with coolant → Anchor. –  Check oil level; A4 → Booklet812, A5 → Booklet811   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.