Removal And Installation: Turbocharger

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2013 Audi A3, 2012 Audi A3, 2011 Audi A3, 2010 Audi A3, and 2009 Audi A3. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Hose Clip Pliers V.A.G 1921
Hose Clip Pliers VAS 6340
Engine Bung Set VAS 6122

CAUTION:

If mechanical damage is found on exhaust turbocharger, for example a destroyed compression wheel, it is not enough to just replace the turbocharger. Perform the following steps to prevent subsequent damage.

Check the air filter housing, the air filter insert and the intake hoses for contamination.
Check entire charge air circuit and cooler for contamination.

If contaminants are found in charge air circuit, circuit must be cleaned and cooler replaced if necessary.

Removing

NOTE:

During installation, cable ties must be installed at the same location.

-- Remove the engine cover -arrows-.

Fig 1: Identifying Engine Cover, Removal

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-- Remove the cover for the air guide; to do so disengage the side clips -arrows-.

Fig 2: Identifying Air Duct Cover Slide Clips

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-- Unclip the lower air guide, to do so disengage the clips -arrows-.

Fig 3: Identifying Lower Air Guide Clips

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-- Remove the lower air guide together with the air guide hose.

-- Disconnect electrical connector -1- on mass air flow (MAF) sensor -G70-.

Fig 4: Identifying Air Flow Housing, Electrical Connector And Guide Hose

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-- Remove the air guide hose -2-.

-- Remove the bolt -4- and the air filter housing.

NOTE:

Ignore -3-.

-- Remove front exhaust pipe with catalytic converter. Refer to FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER .

-- Remove the right front wheel.

-- Remove noise insulation. Refer to Removal and Installation .

-- Loosen the fasteners -1, 2 and 3- and remove the right noise insulation.

Fig 5: Identifying Removal Of Left And Right Front Part Of Wheel Housing Liner

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Cabriolet

-- Remove the noise insulation bracket. Refer to Removal and Installation .

All

-- Drain coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .

-- Remove bolts -arrows-.

Fig 6: Identifying Air Guide Pipe And Bolts

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-- Remove the air guide pipe by lifting the clamps -1 and 2-.

-- Disconnect the connectors -1 and 2- and free up the wire -arrows-.

Fig 7: Identifying Turbocharger Electrical Connectors

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-- Remove bolts -1 and 2- and remove the turbocharger support.

Fig 8: Identifying Turbocharger Support And Bolts

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-- Remove the banjo bolt -2- and move the coolant line to the side.

Fig 9: Identifying Oil Return Line, Coolant Line And Oil Supply Line Fasteners

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-- Remove the bolts -1- on the oil return line.

-- Remove the bolt -3- on the oil supply line.

NOTE:

The installation location is shown with the engine removed.

-- Press the release buttons, remove the air guide hose -2- and move them to the side.

Fig 10: Identifying Air Guide Hose, Pipe And Bolts

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-- Remove the air guide pipe bolts -arrows-.

CAUTION:

Risk of violating emissions legislation.

Do not open hose connection -1- !

-- Lay aside the air guide pipe with the connected crankcase ventilation hose -1-. Loosen the hose clamp -3- to do so.

-- Disconnect the oil supply line from the turbocharger -1-.

Fig 11: Identifying Turbocharger And Heatshield

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-- Remove the coolant hoses -4 and 5-.

Fig 12: Identifying Vacuum Pump, Ground Cable, Electrical Connector And Coolant Hoses

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-- Remove Ground (GND) wire -2-.

-- Remove the EVAP canister with the connected lines upward out of the bracket -arrow- and lay it aside.

Fig 13: Identifying EVAP Canister

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-- Disconnect the coolant hose -arrow-.

Fig 14: Identifying Coolant Hose Clamps

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-- Remove the nuts -arrows-.

Fig 15: Identifying Turbocharger/Exhaust Manifold Upper Nuts

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-- Remove the turbocharger with the exhaust manifold upward.

Installing

Tightening specifications, refer to TURBOCHARGER ASSEMBLY OVERVIEW .

Installation is in reverse order of removal, note the following:

NOTE:

Replace the seals, O-rings and the self-locking nuts.

Fill the turbocharger with engine oil at the oil supply line connection.

Hose connections and charge air system hoses must be free of oil and grease before installing.

Secure all hose connections with hose clamps appropriate for the model.

-- Install the turbocharger and exhaust manifold; tightening sequence TURBOCHARGER ASSEMBLY OVERVIEW .

-- Install the front coolant pipes. Refer to FRONT COOLANT PIPES .

-- Installing front exhaust pipe with catalytic converter. Refer to FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER .

-- Install exhaust system free of stress. Refer to EXHAUST SYSTEM, ALIGNING .

-- Air Guides, Installing with Connector. Refer to HOSE CONNECTIONS WITH CONNECTOR COUPLINGS, ASSEMBLING

-- Fill with coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .

-- Check oil level. Refer to Maintenance, Diagnosis

NOTE:

After installing turbocharger, let engine idle for approximately 1 minute without increasing engine speed. This ensures adequate oil supply to the turbocharger.