Turbocharger Seal, Replacing: Installing

WARNING: This page is about a different car, the 2024 Audi RS 3. However, it is still accessible from the selected car via links, so may be relevant.

Install in the reverse order of removal while noting the following:

Replace bolts that were tightened with an additional turn after removing them.
Replace seals, gaskets, O-rings and self-locking nuts after disassembly.
Coat the turbocharger stud bolts with hot bolt past. Refer to the Parts Information.
Fill the turbocharger with engine oil at the oil supply line connection.
Secure all hose connections with hose clamps that match the ones used in series production. Refer to the Parts Information.
After installing the turbocharger, let the engine idle for approximately one minute without increasing the engine speed. This ensures adequate oil supply to the turbocharger.
Used coolant cannot be used again.

To ensure the settling of the exhaust manifold gasket, the exhaust manifold must be bolted as follows.

Turbocharger with exhaust manifold - tightening specifications and sequence

Fig 1: Identifying Turbocharger - Tightening Sequence

Courtesy of AUDI OF AMERICA, LLC

Replace the nuts after removing.

-- Tighten the bolts in stages in the sequence shown:

Step	Nuts	Tightening Specification
1.	-1 to 6-	Tighten until it makes contact
2.		Hammer the manifold downward with a suitable tool (such as a curved pry bar) and a hammer (so that the manifold sits deeper in the lower flange).
3.	-1 to 6-	Pre-tightening: 15 Nm
4.		Hammer the manifold downward again with a hammer (so that the manifold sits deeper in the flange).
5.	-1 to 6-	25 Nm
6.	-1 to 6-	30 Nm
7.	-1 to 6-	Tighten a quantity of 6 to 30 Nm ¹⁾
¹⁾ These measures take into account the shrinkage of the turbocharger seal.

Turbocharger tensioning bracket - tightening specifications and tightening sequence

Fig 2: Turbocharger Tensioning Bracket - Tightening Specifications and Tightening Sequence

Courtesy of AUDI OF AMERICA, LLC

Replace the nuts after removing.

-- Tighten the nuts in the sequence shown -1 to 6- to 30 Nm.

Heat shield - tightening specification

Fig 3: Heat Shield

Courtesy of AUDI OF AMERICA, LLC

Heat shield, version 1:

-- Tighten the bolts -arrows- to 9 Nm.

Heat shield, version 2:

Courtesy of AUDI OF AMERICA, LLC

-- Tighten the bolts -arrows- to 9 Nm.

-- Tighten the bolts -1- to 9 Nm.

Vacuum Diaphragm - Tightening Specification

Fig 4: Vacuum Diaphragm

Courtesy of AUDI OF AMERICA, LLC

Clip - replace after removing
Lock Nut - 7 Nm
Nut - 7 Nm

-- Install the catalytic converter. Refer to CATALYTIC CONVERTER, REMOVING AND INSTALLING .

-- Install the Oxygen Sensor 1 Before Catalytic Converter -GX10-. Refer to HEATED OXYGEN SENSOR, REMOVING AND INSTALLING .

-- Install the air filter housing. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

-- Check the oil level. Refer to ENGINE OIL .

-- Fill the coolant. Refer to COOLANT, DRAINING AND FILLING .