Audi Workshop Service and Repair Manuals

Removing and installing turbocharger Special tools and workshop equipment required

t  Engine bung set -VAS 6122- 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 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 lock carrier cover -4- → Rep. gr.63. –  Remove particulate filter: t  Vehicles with manual gearbox/ multitronic gearbox 0AW → Chapter t  Vehicles with dual clutch gearbox 0B5 → Chapter.

–  Remove bolts -arrows-. –  Detach air duct -1- from intermediate flange -2- for air cleaner housing.

–  Remove bolts -2 and 3-. –  Release hose clip -1- and detach air pipe.

–  Remove bolts -1 and 2-.

–  Press release tabs and detach crankcase breather hose -1-.

–  Unplug electrical connector -arrow-.

–  Remove bolts -2-. –  Release screw-type clip -1- and detach exhaust gas recirculation pipe.

–  Detach electrical connector -2- from bracket and unplug. –  Move clear electrical wiring.   Note Disregard -item 1-.

–  Loosen bolt -5-. –  Remove nuts -1 and 2- and bolts -3 and 4-. –  Remove turbocharger. Installing Installation is carried out in the reverse order; note the following: Tightening torques: l  → Chapter „Turbocharger - exploded view“. l  → Fig. „„Turbocharger - tightening torque and sequence““. l  → Fig. „„Exhaust gas recirculation pipe to turbocharger - tightening torque and sequence““. l  → Chapter „Charge air cooler - exploded view“. l  → Fig. „„Installing air hoses with screw-type clips““.   Note t  Renew gaskets and O-rings. t  Fill turbocharger with engine oil at connection for oil supply line. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue. t  After installing the turbocharger, allow the engine to idle for approx. 1 minute without pressing the accelerator to ensure that the turbocharger is supplied with oil. –  Electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations. –  Install air duct → Rep. gr.23. –  Install particulate filter: t  Vehicles with manual gearbox/ multitronic gearbox 0AW → Chapter t  Vehicles with dual clutch gearbox 0B5 → Chapter. –  Install lock carrier cover → Rep. gr.63. –  Fill up with coolant → Anchor.