Turbocharger, Removing And Installing, Vehicles With Two Turbochargers: Removing

WARNING: This page is about a different car, the 2015 Audi A7 Quattro and 2014 Audi A7 Quattro. However, it is still accessible from the selected car via links, so may be relevant.

WARNING:

When working on the whole exhaust system:

Follow the safety precautions when working on the exhaust system, refer to EXHAUST SYSTEM SAFETY PRECAUTIONS .

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.

NOTE:

Follow all the rules of cleanliness, refer to CLEAN WORKING CONDITIONS .

-- Remove the air filter housing, refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

-- Drain the coolant, refer to COOLANT, DRAINING AND FILLING .

-- Remove the plenum chamber bulkhead, refer to Bulkhead .

CAUTION:

Danger of causing damage to electronic components.

Observe the steps for disconnecting the battery.

-- Disconnect the ground cable from the battery terminal, refer to [For engine(s) CTUA,CEUC,CRDB,CGXB,CPNB] Removal and Installation .

-- Release the retainer -arrow A- and open the cover -arrow B-.

Fig 1: Identifying Retainer

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-- Disconnect the connector -1-.

Fig 2: Identifying Connector & Fasteners

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-- Remove the nuts -2, 3 and 4- move the wire to the side.

NOTE:

Ignore the -arrows-.

Vehicles with an SCR system:

Fig 3: Identifying Connector And Bolts

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-- Remove the nuts -2 and 3- and free up the wire.

-- Remove the connector -1- from the bracket and disconnect it.

NOTE:

Ignore the -arrows-.

Continuation for All Vehicles:

Fig 4: Identifying Heater Core Hoses

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NOTE:

Use a cloth to catch any leaking coolant.

-- Loosen hose clamps -2, and 3- and remove the Coolant Hose -1, and 4- from the Heater Core.

NOTE:

Ignore Hose Clamps - Up To 25mm3094.

-- Disconnect electrical connectors -1 through 4- and move the wiring harness to the side.

Fig 5: Identifying Connectors

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Fig 6: Identifying Bolts And Pipe

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CAUTION:

Danger of causing damage to Turbocharger shaft.

The compressor blade shaft extends over the contour of the turbocharger housing.
Do not damage the compressor blade when removing the connecting pipe.

-- Remove the bolts -arrows- and the connecting pipe -1-.

-- Remove the front exhaust pipe, refer to EXHAUST PIPE, REMOVING AND INSTALLING, VEHICLES WITH TWO TURBOCHARGERS. .

-- Remove the Exhaust Gas Temperature Sensor 3 -G495- -item 1- and pressure pipe -3- for the Differential Pressure Sensor -G505-.

Fig 7: Differential Pressure Sensor - G505- Component Location

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NOTE:

Ignore -item 2-.

-- Remove from the bracket and disconnect connector -1- and if equipped -4-.

Fig 8: Heated Oxygen Sensor -G39-

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-- If equipped, unbolt and remove the Exhaust Gas Temperature Sensor 2 -G448- -item 3-.

NOTE:

Ignore -item 2-.

Vehicles with an SCR system:

Fig 9: NOx Sensor -G295- Component Location

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-- Remove the NOx Sensor -G295- -arrow- free up and set to the left side.

Continuation for All Vehicles:

Fig 10: Identifying Nuts

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-- Remove the nuts -arrows- and push the catalytic converter to the rear, while doing this on vehicles with a selective catalytic reduction system pay attention to the catalytic converter wires.

-- Remove the bolts -arrows- and remove the heat shield -1-.

Fig 11: Identifying Heat Shield Bolts

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-- Remove the bolts -arrows-.

Fig 12: Identifying Bolts

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-- Remove vacuum hose -1- and press the Vacuum Line to the side.

-- Remove the banjo bolts -arrow-, and remove the Oil supply line -1-.

Fig 13: Identifying Banjo Bolts And Oil Supply Line

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Remove bolts -3, and 4- and Union nut -1, and 2- for the coolant supply line.

Fig 14: Identifying Bolts And Union Nut

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-- Loosen the clamp -2- and remove the coolant hose.

Fig 15: Identifying Clamp And Bolts

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NOTE:

Ignore -items 1 and 3-.

-- Remove vacuum hose -2- and free up the Vacuum Line -1- from the flange.

Fig 16: Identifying Vacuum Hoses

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-- Press the release buttons and remove the crankcase ventilation hose -1-.

Fig 17: Identifying Crankcase Ventilation Hose

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-- Remove the bolt -1-.

Fig 18: Identifying Bolt

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NOTE:

Ignore -item 2-.

-- Remove the bolts -arrows-.

Fig 19: Identifying Bolts And Intermediate Pipe

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-- Remove the right air guide pipe -2- along with the intermediate pipe -1- from the turbocharger assembly and set aside.

NOTE:

Ignore -item 3-.

-- Loosen bracket -1- and remove Bypass valve -2-.

Fig 20: Identifying Bracket And Bypass Valve

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-- Remove the bolts -1- and move tab to the side.

Fig 21: Identifying Bolts

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-- Remove the left and right bolts -1-.

Fig 22: Identifying Brace & Bolts

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-- Loosen the right and left bolts -3- at the bracket -2- for the turbocharger.

-- Loosen the left and right brackets -arrow- and slide it onto the exhaust manifold.

Fig 23: Identifying Clamp

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Fig 24: Identifying Oil Return Pipe And Bolts

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CAUTION:

Danger of causing damage to the Oil Return Pipe.

Do not bend the Oil Return Pipe.

-- Remove the screws -1- from the Oil Return Pipe.

NOTE:

Ignore -item 2-.

-- Remove the screws -2- on the EGR pipe.

Fig 25: Identifying EGR Pipe, Screws And Clamp

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NOTE:

Ignore -item 1-.

-- Remove the bolts -1, 2, and 3-.

Fig 26: Identifying Bolts

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Fig 27: Identifying Engine Support Bridge Components And Turbocharger Assembly

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WARNING:

Loose engine support bridge components could cause an accident.

Secure the mounting hooks and pins on the engine support bridge using securing pins -arrows-.

CAUTION:

Danger of causing damage to Turbocharger shaft.

The Turbocharger shaft extends over the contour of the housing.

-- Hook the Engine Sling 2024A to the turbocharger and to the Shop Crane VAS 6100.

-- Carefully lift the turbocharger assembly.

Disconnect the turbocharger:

Fig 28: Identifying Clamp And Bolts

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-- Remove the banjo bolts -1 and 3- and remove the coolant supply line.

NOTE:

Ignore -item 2-.

-- Remove the bolts -arrows- and remove the intermediate flange -1-.

Fig 29: Identifying Bolts

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-- Remove the bolts -2 to 6- and the nuts -1 and 7-, and disconnect the turbocharger.

Fig 30: Identifying Turbocharger Assembly Fasteners

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