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

WARNING: This page is about a different car, the 2016 Audi A6 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..

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.
Possible cause for mechanical fault in the turbocharger can be foreign objects from the exhaust manifold.
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..

-- 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 BATTERY .

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

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-- Disconnect the connector -1-.

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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:

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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:

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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 25mm :3094 .

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

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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.

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

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NOTE:

Ignore -item 2-.

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

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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:

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

Continuation for All Vehicles:

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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-.

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-- Remove the bolts -arrows-.

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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-.

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

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

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NOTE:

Ignore -items 1 and 3-.

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

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

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-- Remove the bolt -1-.

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NOTE:

Ignore -item 2-.

-- Remove the bolts -arrows-.

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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-.

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

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

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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.

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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.

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NOTE:

Ignore -item 1-.

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

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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 : VAS6100 .

-- Carefully lift the turbocharger assembly.

NOTE:

The turbocharger must not be separated.