Removing and installing turbocharger, engine code AGR — AUDI

AHF ALH ASV
Removing

Remove oil dipstick -1- from guide tube.
Unclip caps.
Unscrew nuts -arrows- and remove engine cover.
Reinsert oil dipstick in guide tube.

Remove air duct hose-1- from air duct pipe.
Detach connector of air mass meter -3-.
Unscrew bolts -4- and -5-.
Remove vent hose -2- from rear of air cleaner housing.
Take out air cleaner housing.

Remove air duct pipe from air filter to turbocharger.

Unscrew oil feed line from exhaust turbocharger and exhaust manifold -arrows-.

Unscrew oil feed line from oil filter bracket -arrow- and also on cylinder head and lay line aside.

Remove bolt -1- from above.

Remove lower air duct pipe -arrows-.

Remove noise insulation in centre and on right -arrows-.

Unbolt heat shield for right drive shaft -arrows-.

Unbolt bracket for exhaust system from assembly mounting -arrows-.

Note:

The isolating element in front exhaust pipe must not be deflected more than 10°to avoid damage.

Unscrew securing bolts -arrows- of front exhaust pipe/exhaust turbocharger.

Detach the exhaust system at the clamping sleeve -arrows-.
Remove the front exhaust pipe.

Disconnect hose to boost pressure control solenoid valve -N75 at turbocharger or unscrew banjo bolt, respectively.
Disconnect hose at boost pressure valve pressure unit.
Remove air duct hoses at turbocharger.
Detach the oil return line at cylinder block -arrow-.

Screw out nut -2- from below.
Remove the turbocharger.

Installing

Installation is carried out in the reverse order; note the following:

Notes:

Always replace seals, gaskets and self-locking nuts.
Note installation position of exhaust manifold/exhaust turbocharger gaskets.
Fill the turbocharger with engine oil via the oil feed connection.
Secure all hose connections with the correct hose clamps (same as original equipment):

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Hose connections and hoses for charge air system must be free of oil and grease before assembly.

Slide the hose onto the boost pressure valve pressure unit and secure it using a hose clamp.

Position turbocharger on exhaust manifold and hand-tighten securing nut -2- after coating it with high-temperature lubricant.

High-temperature lubricant

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Coat threads and bolt head contact surface of securing bolts -1- with high temperature lubricant.
Tighten the securing bolts -1- to 30 Nm and the fastening nut -2- to 25 Nm.
Install exhaust system and align it stress-free => Page
26-13
.
Check oil level => Page
17-21
.

Note:

After installing the turbocharger, run engine for approx. 1 minute at idling speed; do not rev up immediately. This ensures the turbocharger is properly lubricated.

Tightening torques

Component · Nm
Turbocharger to exhaust manifold
Bolt · 30 1)3)
Nut · 25 2)3)
Oil return line to cylinder block · 40
Oil feed line to turbocharger · 22
Oil feed line to
Oil filter bracket · 25
Bracket · 10

1)
Replace bolts

2)
Replace the nuts.

3)
Coat threads and bolt head seating surface with high-temperature lubricant;
High-temperature lubricant

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