Audi Cars 1999-05

Turbocharger

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Removal & Installation



1.8L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine undercover.
  4.  
  5. Remove the air conditioning compressor mounting fasteners. Remove the compressor leaving the lines attached. Support the compressor such that the lines are not stretched or kinked.
  6.  
  7. Unbolt the turbocharger support bracket.
  8.  
  9. Disconnect the oil return line at the turbocharger.
  10.  
  11. Remove the air hoses from the turbocharger.
  12.  
  13. Disconnect the oil feed line at the turbocharger.
  14.  
  15. Disconnect the hose for the boost pressure regulation valve vacuum diaphragm.
  16.  
  17. Unbolt the bracket for the coolant supply line at the boost pressure regulation valve vacuum diaphragm.
  18.  
  19. Using clamp Tool No. 3094, or equivalent, pinch off the coolant supply hose.
  20.  
  21. Remove the intake air duct between the cowl and the air cleaner housing.
  22.  
  23. Remove the air cleaner housing cover.
  24.  
  25. Label and detach the following lines and electrical connectors:
  26.  


    Wastegate bypass regulator valve
     
    Evaporative Emission (EVAP) canister purge regulator valve
     
    Power outage stage
     
    Mass Air Flow (MAF) sensor
     

  27. Remove the air cleaner housing and the engine cover.
  28.  
  29. Disconnect the crankcase breather hose at the valve cover.
  30.  
  31. Disconnect the oil supply line at the turbocharger.
  32.  
  33. Remove the heat shield, and sleeve from the coolant return hose.
  34.  
  35. Using clamp Tool No. 3094, or equivalent, pinch off the coolant return hose, then remove.
  36.  


WARNING
The exhaust flexpipe may be damaged if bent more than 10°.

  1. Disconnect the Three Way Catalytic Converter (TWC) from the turbo.
  2.  
  3. Unbolt the turbo from the exhaust manifold.
  4.  
  5. Move the turbo aside to disconnect the coolant supply banjo fitting.
  6.  
  7. Remove the turbo.
  8.  



Click image to see an enlarged view

Fig. exploded view of the turbocharger and related components-1.8L Engine



Click image to see an enlarged view

Fig. Exploded view of the vacuum hoses related to the turbocharger-1.8L Engine



Click image to see an enlarged view

Fig. The turbo-charger as viewed from the engine compartment

To install:

  1. Install the turbo, coating the fasteners with Hot Bolt Paste, G 052 112 A3 or equivalent.
  2.  
  3. Connect the coolant supply banjo fitting and tighten to 18 ft. lbs. (25 Nm).
  4.  
  5. Using new gaskets, install the turbocharger to the exhaust manifold, coat the bolts with Hot Bolt Paste, then tighten the mounting bolts to 26 ft. lbs. (35 Nm). Tighten the turbo support bracket mounting bolts to 33 ft. lbs. (45 Nm).
  6.  
  7. Attach the TWC converter to the turbo.
  8.  
  9. Connect the coolant supply hose.
  10.  
  11. Install the sleeve and heat shield to the return hose.
  12.  
  13. Connect the oil return hose.
  14.  
  15. Make sure the openings are clear and clean. Add fresh engine oil to the turbo through the oil feed line.
  16.  
  17. Connect the oil supply line to the turbo and tighten to 18 ft. lbs. (25 Nm).
  18.  
  19. Connect the crankcase breather, then install the engine cover and air cleaner housing.
  20.  
  21. Attach the following lines and electrical connectors:
  22.  


    Mass Air Flow (MAF) sensor
     
    Power outage stage
     
    Wastegate bypass regulator valve
     

  23. Connect the hoses and brackets for the boost pressure regulation valve vacuum diaphragm.
  24.  
  25. Connect the air hoses to the air cleaner assembly and the turbo.
  26.  
  27. Install the air conditioning compressor and engine undercovers.
  28.  
  29. Refill the coolant system and bleed as necessary. For additional information, please refer to the following topic(s): General Information and Maintenance, Fluids and Lubricants.
  30.  
  31. Check the oil level and top off as necessary.
  32.  
  33. Connect the negative battery cable.
  34.  
  35. Enter the radio security code.
  36.  
  37. Start the vehicle and check for leaks, then let the engine idle for approximately 1 minute without increasing the engine speed. This ensures adequate oil supply to the turbo.
  38.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Engine undercover
     
    Air conditioning compressor and move it aside with the lines attached
     
    Turbocharger support bracket
     
    Oil return line at the turbocharger
     
    Air hoses from the turbocharger
     
    Oil feed line at the turbocharger
     
    Hose for the boost pressure regulation valve vacuum diaphragm
     
    Bracket for the coolant supply line at the boost pressure regulation valve vacuum diaphragm
     
    Coolant supply hose by pinching it off using Clamp tool 3094
     
    Intake air duct between the cowl and the air cleaner housing
     
    Air cleaner housing cover
     

  4.  
  5. Label and detach the following lines and electrical connectors:

    Wastegate bypass regulator valve
     
    Evaporative Emissions (EVAP) canister purge regulator valve
     
    Power outage stage
     
    Mass Air Flow (MAF) sensor
     

  6.  
  7. Remove or disconnect the following:
    NOTE
    The exhaust flex pipe may be damaged if bent more than 10 degrees.



    Air cleaner housing and the engine cover
     
    Crankcase breather hose at the valve cover
     
    Oil supply line at the turbocharger
     
    Heat shield and sleeve from the coolant return hose
     
    Coolant return hose by pinching it off using Clamp tool 3094 first
     



    Three-Way Catalytic Converter (TWC) from the turbo
     
    Turbo from the exhaust manifold
     
    Coolant supply banjo fitting at the turbocharger
     
    Turbocharger
     

  8.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the turbocharger and related components-1.8L engine



Click image to see an enlarged view

Fig. Exploded view of the vacuum hoses related to the turbocharger-1.8L engine

  1. Installation is the reverse of the removal procedure, while using the following torque values:

    Coolant supply banjo fitting: 18 ft. lbs. (25 Nm)
     
    Turbocharger exhaust manifold bolts: 26 ft. lbs. (35 Nm)
     
    Turbo support bracket bolts: 33 ft. lbs. (45 Nm)
     
    Turbo oil supply line: 18 ft. lbs. (25 Nm)
     

  2.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain coolant
  4.  
  5. Drain engine oil
  6.  
  7. Remove or disconnect the following:
    NOTE
    The exhaust flex pipe may be damaged if bent more than 10 degrees.



    Negative battery cable
     
    Engine cover
     
    Noise insulation under engine
     
    Heat shield for right drive axle
     
    Right drive axle
     
    Front exhaust pipe
     



    Air hose between upper air line and lower air line
     
    Bracket for upper air line
     
    Oil return line
     
    Turbocharger bracket from cylinder block
     
    Bracket for coolant return line
     
    Coolant supply line from cylinder block
     
    Hose from pressure unit for charge air pressure control
     
    Turbocharger support bracket
     
    Oil return line
     
    Air hoses
     
    Pressure control valve
     
    Connector from charge air pressure control valve
     
    Vacuum line from air recirculation valve
     
    Air intake hose from air cleaner
     
    Pull locking clip out of turbocharger connection and take off air intake hose
     
    Coolant return hose from the Y connection on the right next to the cylinder head
     
    Heat shield on back of cylinder head
     
    Turbocharger from exhaust manifold
     
    Exhaust manifold
     
    Retainer piece for oil supply line from turbocharger
     
    Oil supply line and coolant return line
     
    Turbocharger
     

  8.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the turbocharger and related components-1.8L engine TT



Click image to see an enlarged view

Fig. Exploded view of the vacuum hoses and connections related to the turbocharger-1.8L engine TT

  1. Installation is the reverse of the removal procedure, while using the following notes and torque values:


  2.  
  3. Bolt turbocharger bracket onto turbocharger but do not tighten bolts
  4.  
  5. Position turbocharger against engine from below, then tighten bolts by hand to secure bracket to cylinder block
  6.  
  7. Tighten bolts for oil supply line
  8.  
  9. Install coolant return line with spacer sleeve and bolt it to the turbocharger
  10.  
  11. Unbolt turbocharger bracket from cylinder block again
  12.  
  13. Install exhaust manifold
  14.  
  15. Bolt turbocharger to exhaust manifold
  16.  
  17. Install or connect the following:

    Coolant supply banjo fitting: 26 ft. lbs. (35 Nm)
     
    Turbocharger exhaust manifold bolts: 18 ft. lbs. (25 Nm)
     
    Turbo support bracket bolts: 22 ft. lbs. (30 Nm)
     
    Turbo return line: 26 ft. lbs. (35 Nm)
     

  18.  

2.7L Engine

NOTE
Turbocharger replacement procedure is given with the engine removed. The 2.7L engine uses turbochargers on both sides of the engine.

Before servicing the vehicle, refer to the precautions section.

Left Side Turbocharger
  1. Remove or disconnect the following:

    Vacuum hoses
     
    Lower section of pressure line
     
    Upper section of intake line
     
    Pressure hose from turbocharger
     
    Hose to turbocharger
     
    Oil return and water lines
     
    Turbocharger
     

  2.  

To install:

  1. Installation is the reverse of the removal procedure, using the following torque values:

    Intake lines: 84 inch lbs. (10 Nm)
     
    Heat shield: 84 inch lbs. (10 Nm)
     
    Oil line to turbocharger: 11 ft. lbs. (15 Nm)
     
    Oil line to intake manifold: 15 ft. lbs. (20 Nm)
     
    Turbocharger: 15 ft. lbs. (20 Nm
     

  2.  

Right Side Turbocharger
  1. Remove or disconnect the following:

    Cover panel from cylinder head cover
     
    Remove hoses
     
    Upper section of intake line
     
    Plug lower section of intake line, then remove line
     
    Vacuum hoses
     
    Bracket with transmission oil lines
     
    Pressure hose from turbocharger
     
    Oil return and water lines
     
    Hose from cylinder head
     
    Turbocharger
     

  2.  

 
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