Removing and installing turbocharger - engine codes BPW, BRB, BRC — AUDI

🧭 Before you start

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

• Renewed: charge air cooler, gaskets

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• 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.
• Disregard items (2) and (3).
• When installing air intake hoses with plug-in connectors, ensure that the securing clip (arrow) engages audibly on the retaining lug (A).

🔧 Engine codes this applies to

📋 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. — Remove front exhaust pipe: vehicles with manual gearbox ; vehicles with multitronic gearbox .
2. Remove particulate filter .
3. Detach air intake hose from turbocharger by lifting retaining clip (arrow) slightly.
4. Remove oil return line at turbocharger (arrow).
5. Remove bracket for turbocharger (arrows).

6. Release quick-release fasteners (1) and (2) and take off noise insulation.
7. Remove bolts (1) and (2) and detach support for turbocharger. [Note: Place a cloth underneath to catch any escaping oil.]
8. Remove oil return line (3) at cylinder block.
9. Unscrew nuts (2) and (3) (accessible from below) connecting turbocharger to exhaust manifold. [Note: Disregard (item 1).]
10. Detach crankcase breather hose (2) from cylinder head cover.
11. Remove bolts (3) and (4).
12. Detach hose (1) between charge air cooler and turbocharger.
13. 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.]
14. Disconnect hose (arrow) from vacuum unit for charge pressure control.
15. Unscrew oil supply line at turbocharger and exhaust manifold (arrows).
16. Unscrew securing nut accessible from above (1) connecting turbocharger to exhaust manifold and remove turbocharger. [Note: Disregard items (2) and (3).]
17. Detach turbocharger. [Note: Renew gaskets, seals and self-locking nuts.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.]
18. When installing air intake hoses with plug-in connectors, ensure that the securing clip (arrow) engages audibly on the retaining lug (A).
19. Install exhaust gas recirculation cooler 23.
20. Install particulate filter .
21. Install front exhaust pipe: vehicles with manual gearbox ; vehicles with multitronic gearbox .
22. Align exhaust system so it is free of stress .
23. 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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