Removing and installing turbocharger- engine codes AVB, AVF, AWX and BKE — AUDI

🧭 Before you start

Fits: Audi A4 Cabriolet B6/B7 (8H), Audi A4 B6/B7 (8E)

• Renewed: charge air cooler, seals

Don't miss

• Before removing, mark direction of rotation of poly V-belt with chalk or felt-tip pen. If the belt runs in the opposite direction when it is refitted, this can cause breakage.
• The air conditioner refrigerant circuit must not be opened. — Unscrew air conditioner compressor from bracket (arrows).
• Place a cloth underneath to catch any escaping oil.
• Disregard (item 1).
• It is not necessary to disconnect the coolant hoses on exhaust gas recirculation cooler.

🔧 Engine codes this applies to

📐 56 workshop diagrams for AVB

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. ⚠ If the turbocharger has suffered mechanical damage (e.g. damaged compressor wheel), it is not sufficient merely to fit a new turbocharger. The following work must be performed in order to avoid further damage:Check air cleaner housing, air filter element and air hoses for dirt and foreign particles.Check the entire charge air system (including the charge air cooler) for foreign matter.If foreign matter is found in the charge air system, clean all relevant ducts and hoses and renew charge air cooler if necessary. — Vehicles with auxiliary heater: remove bolts (arrows) securing exhaust pipe for auxiliary/additional heater to noise insulation.
2. Release quick-release fasteners (1) and (2) and take off front noise insulation. Leave rear noise insulation in position. [Note: Before removing, mark direction of rotation of poly V-belt with chalk or felt-tip pen. If the belt runs in the opposite direction when it is refitted, this can cause breakage.]
3. Loosen securing bolts of tensioning roller for air conditioner compressor poly V-belt (arrows).
4. Remove poly V-belt.
5. Unscrew bracket for refrigerant line (1).

6. Disengage refrigerant line at bracket (2).
7. Unplug electrical connector (1) for magnetic clutch of air conditioner compressor.
8. ⚠ The air conditioner refrigerant circuit must not be opened. — Unscrew air conditioner compressor from bracket (arrows).
9. Tie up air conditioner compressor with pipes attached to right-side of vehicle.
10. Detach air intake hose (1) at bottom of turbocharger by slightly lifting retaining clip.
11. Remove oil return line at turbocharger (arrow).
12. Remove bracket for turbocharger (arrows).
13. Remove bolts (1) and (2) and detach support for turbocharger. [Note: Place a cloth underneath to catch any escaping oil.]
14. Remove oil return line (3) at cylinder block.
15. Unscrew nuts (2) and (3) (accessible from below) connecting turbocharger to exhaust manifold. [Note: Disregard (item 1).]
16. Unclip cover caps.
17. Unscrew nuts (arrows) and detach engine cover panel. Also pull out dipstick if necessary.
18. Remove insulation beneath cover panel (if fitted).
19. Remove bolts (arrows).
20. Remove air ducts (1) and (2).
21. Unplug electrical connector (1) at air mass meter G70.
22. Loosen hose clip (2) to remove air intake hose.
23. Move clear wiring harness at air cleaner housing and remove air cleaner housing (arrow).
24. Remove intake manifold together with exhaust gas recirculation cooler 23. [Note: It is not necessary to disconnect the coolant hoses on exhaust gas recirculation cooler.]
25. Disconnect air intake hose from turbocharger (arrows).
26. Pull hose (2) off vacuum unit for charge pressure control.
27. Unscrew bolt (1) from bracket for oil supply line.
28. Unscrew oil supply line (3) at turbocharger.
29. Unscrew nuts securing turbocharger to front exhaust pipe (arrows).
30. Unscrew upper securing nut (1) for turbocharger.
31. Detach turbocharger. [Note: Renew seals, gaskets and self-locking nuts.Pay attention to installation position of exhaust manifold/turbocharger gasket.Fill turbocharger with engine oil at connection for oil supply line.Charge air system must be free of leaks.Hose connections and hoses for charge air system must be free of oil and grease before assembly.Secure all hose connections with the correct type of hose clips (same as original equipment) Electronic parts catalogue.To ensure that the charge air hoses can be properly secured at their connections, spray rust remover onto the worm thread of used hose clips before installing.]
32. When installing air intake hoses with plug-in connectors, ensure that the securing clip (arrow) engages audibly on the retaining lug (A).
33. Install exhaust system and align it free of stress .
34. Install intake manifold together with exhaust gas recirculation cooler 23.
35. Install poly V-belt .
36. Check oil level 803 or 805. [Note: After installing turbocharger, allow engine to idle for approx. 1 minute and do not rev up immediately to ensure turbocharger is supplied with oil.]

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