Turbocharger, removing and installing

WARNING: This page is about a different car, the 2009 Audi A4, 2008 Audi A4, 2007 Audi A4, 2006 Audi A4, and 2005 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Special tools, testers and auxiliary items required

Fig 1: Identifying Spring-Type Clip Pliers VAS 5024 A

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Spring-type clip pliers VAS 5024 A

Removing

Fig 2: Removing Engine Cover

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove engine cover - arrows -.

CAUTION: Cover cap of expansion tank with rag and open carefully, as hot steam or hot coolant may escape when opening.

Open cap of coolant expansion tank.
Drain engine coolant → Cooling system, draining and filling

Fig 3: Removing Heat Shield

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove heat shield - arrows -.

Fig 4: Identifying Crankcase Ventilation With Heat Shield, Crankcase Ventilation From Cylinder Head Cover, Oil Supply Line & EVAP Canister Line

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove crankcase ventilation line from turbocharger - 1 -.
Pull off crankcase ventilation line from the cylinder head cover - 2 - and remove it.
Disconnect EVAP line to turbocharger from cylinder head cover - 3 -.
Remove oil supply line from turbocharger - 4 -.

Remove catalytic converter → Catalytic converter, removing and installing

Fig 5: Removing Coolant Supply Line To Turbocharger

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove coolant supply line to turbocharger - arrow -.

Fig 6: Identifying Exhaust Pipe Fasteners

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

Fig 7: Identifying Quick-Release Fasteners And Noise Insulation

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation.
Remove quick-release fasteners - 3 - and remove rear noise insulation, if installed.

Fig 8: Removing Air Duct Hoses

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove air duct hose - 1 - to turbocharger at bottom right.
Remove air duct hose to charge air cooler at lock carrier - 2 -

Fig 9: Disconnecting Connector & Separating Intake Hose

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect connector - 1 and 2 - and free up cable.

Fig 10: Removing Oil Supply Line For Turbocharger At Cylinder Block & Bolting Of Support For Turbocharger

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove oil supply line for turbocharger at cylinder block - 1 -.
Remove bolt - 2 - of support for turbocharger.

Fig 11: Removing Oil Supply Line For Turbocharger

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove oil supply line for turbocharger - arrows -.

Fig 12: Disconnecting Oil Return Line From Turbocharger

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect oil return line - arrows - from turbocharger.

Fig 13: Locating Bolt Of Support For Turbocharger

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Loosen bolt - 1 - of support for turbocharger by 2 turns.

Fig 14: Disconnecting Coolant Pipe

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect coolant pipe - arrow -.

Fig 15: Removing Coolant Pipe From Cylinder Head

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove coolant pipe - 1 - , if present, from cylinder head.

NOTE:

Nuts on bottom of fastening strip do not need to be opened

Remove upper nuts - arrows -.
Remove turbocharger/exhaust manifold upward.

Installing

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

NOTE:

Always replace seals, gaskets and self-locking nuts.
Add oil to turbocharger through oil feed line connecting piece.
Hose connections and charge air system hoses must be free of oil and grease before installing.
Secure all hose connections using hose clamps appropriate for the model type .

Install exhaust system and align it free of tension → Exhaust system, installing tension free .
Fill with coolant → Cooling system, draining and filling .
Check oil level →
- 01 - MAINTENANCE
- 01 - MAINTENANCE for MAINTENANCE PROCEDURES - CABRIOLET

NOTE:

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

Torque specifications

Component		Nm
Exhaust manifold/turbocharger to cylinder head		21 ¹⁾²⁾
Oil supply line to exhaust turbocharger		30
Bracket for oil supply line to exhaust manifold		20 ²⁾
Bracket for turbocharger to cylinder block		30 ²⁾
Turbocharger bracket to turbocharger		30 ²⁾
Oil return line to turbocharger		9
¹⁾ Replace bolt or nut ²⁾ Coat studs of exhaust manifold and threads of oxygen sensor with hot bolt paste; Hot bolt paste