Turbocharger, Removing And Installing: Removal

WARNING: This page is about a different variant/trim than selected.

CAUTION:

If mechanical damage (such as a destroyed compression wheel) is found on the turbocharger, just replacing the turbocharger is not enough. To avoid damage later, perform the following steps:

Check the air filter housing, air filter element and air guide hoses for contamination.
Check the entire charge air circuit and charge air cooler for foreign objects.
If there are foreign objects in the charge air system, clean the charge air circuit and replace the charge air cooler if necessary.

-- Carefully pull the engine cover off the 4 bolts one after the other -arrows-.

Fig 1: Removing Engine Cover

GWWA10-11000

Courtesy of AUDI OF AMERICA, LLC

-- Remove the air guide hose by loosening the hose clamps -arrows-.

Fig 2: Locating Spring Clamps

GWWA10-10495

Courtesy of AUDI OF AMERICA, LLC

Vehicles through 05/2010:

-- Remove the bolts -2- and -3-.

Fig 3: Right Side Air Guide Hose, Removing And Installing

GWWA21-10385

Courtesy of AUDI OF AMERICA, LLC

-- Loosen the clamp -1- and remove the air guide hose from the right air guide pipe.

Vehicles from 06/2010:

Fig 4: Removing Air Guide Hose From Right Air Guide Pipe

GWWA21-10027

Courtesy of AUDI OF AMERICA, LLC

-- Remove the bolts -2- and -3-.

-- Loosen the clamp -1- and remove the air guide hose from the right air guide pipe.

All vehicles:

Fig 5: Identifying Air Intake Connector & Air Duct Hose

GWWA21-10018

Courtesy of AUDI OF AMERICA, LLC

-- Remove the bolts -left arrows- and move the air intake connection to the side with the air duct hose still connected -right arrow-.

-- Disconnect the connector -2- on the Turbocharger 1 Servo Motor -V280-.

Fig 6: Identifying Bolt -1- And Banjo Bolt -3- And Move Turbocharger Oil Supply Line To Side

GWWA21-10370

Courtesy of AUDI OF AMERICA, LLC

-- Remove the bolt -1- and banjo bolt -3- for the oil supply line on the turbocharger.

-- Remove the bolts -1- and -2- and then remove the heat shield from the turbocharger.

Fig 7: Identifying Bolts -1 To 2- And Turbocharger Heat Shield

GWWA21-10380

Courtesy of AUDI OF AMERICA, LLC

-- Remove the nuts -arrows- and remove the primary catalytic converter from the turbocharger.

Fig 8: Identifying Front Exhaust Pipe With Catalytic Converter Nuts

GWWA26-10329

Courtesy of AUDI OF AMERICA, LLC

-- Disconnect the -1- Exhaust Gas Temperature Sensor 1 -G235- connector (black).

Fig 9: Identifying Connectors -1 And 2-

GWWA15-10650

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Ignore -item 2-.

-- Remove the turbocharger bolts -arrows-.

Fig 10: Locating Turbocharger Bolts

GWWA21-10226

Courtesy of AUDI OF AMERICA, LLC

Fig 11: Identifying Turbocharger Components

GWWA21-10095

Courtesy of AUDI OF AMERICA, LLC

CAUTION:

Danger of damaging both pipes for the oil return line.

The upper part -3- of the oil return line mounted to the turbocharger must be removed carefully from the lower part -5- of the oil return line.
Gently turning the turbocharger -4- back and forth and pulling it up will prevent bending the oil return line pipes.

O-Ring
Intermediate Flange

-- Remove the turbocharger.

-- Seal any open lines and connections with a clean plug from the Engine Bung Set VAS 6122.

NOTE:

Do not set the removed turbocharger on top the upper part of the oil return line.