Removing and installing turbocharger, engine codes AHF, ALH, ASV — 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 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.

Remove air duct hoses -2- and -3- from turbocharger.
Unscrew turbocharger bracket -1-.
Remove oil return line -4- at cylinder block.

Remove intake manifold => Page
15-14
.
Remove the vacuum hose -arrow- and expose.

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.

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.

Unscrew nuts -arrows-.
Remove packing plates.
Remove the exhaust manifold/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):

=> Parts List

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

Install intake manifold => Page
15-18
.
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
Exhaust manifold/exhaust turbocharger to cylinder head · 25 1)
Oil feed line to turbocharger · 22
Oil feed line to
Oil filter bracket · 25
Bracket · 10
Heat shield to exhaust manifold/exhaust turbocharger · / 25

1)
Replace self-locking nuts.

Component · Nm
Bracket for turbocharger to
cylinder block · 40
turbocharger · 25
Oil return line to cylinder block · 40