Removing and installing turbocharger, single turbo — AUDI

🔧 Engine codes this applies to

📋 Procedure

1. Disconnect electrical connector (1).
2. Loosen clamps (2).
3. Unclip holder (3).
4. Pull off upper intake hose (4).
5. Unscrew bolts (1).

6. Pull off charge air hose (2).
7. Unscrew bolts (3).
8. Detach heat shield (4).
9. Unscrew banjo bolt (5).
10. If present, remove propshaft 39Propshaft; Removing and installing propshaft.
11. Remove catalytic converter .
12. Remove rear engine support .
13. Disconnect connectors (1).
14. Pull off vacuum hose (2).
15. Release and pull off pipe (3).
16. Loosen clip (4).
17. Remove bolt (5).
18. Pull off lower intake hose (6).
19. Remove rear exhaust gas recirculation pipe .
20. Unscrew bolts (1).
21. Swing coolant pipe (2) aside slightly.
22. Remove bolt (1).
23. Swing coolant pipe (2) aside slightly.
24. Disconnect electrical connector (6).
25. Unscrew bolts (3).
26. Detach heat shield (4).
27. Unscrew exhaust gas temperature sender 1G235(5).
28. Move exhaust gas temperature sender 1G235(5) aside to prevent if from becoming damaged.
29. Unscrew bolts (3).
30. Only loosen bolts (2).
31. Remove bolt (1).
32. Unscrew studs (1 … 8) using bit XZN 10T10385.
33. Carefully remove turbocharger (9).
34. Observe tightening sequence for turbocharger .
35. Renew seals, gaskets, O-rings and self-locking nuts after removal.
36. Fill turbocharger with engine oil at connection for oil supply line.
37. Hose unions and air intake pipes and hoses must be free of oil and grease before installation.
38. Secure all hose connections with the hose clips corresponding to original equipment Electronic Parts Catalogue.
39. After installing turbocharger, run engine for about 1 minute at idling speed to ensure that oil is supplied to turbocharger. [Note: After new components have been installed (engine/short engine, cylinder head, camshaft housing or turbocharger) the oil pressure control must be set to max. pressure for approx. 1000 km if the function is available in the engine control unit. This will compensate for the increased friction during run-in of new components, and a better transport of wear-related particles is guaranteed.]
40. Connect .
41. Switch ignition on.
42. Activate oil pressure regulation , 01 - Systems capable of self-diagnosis, 01 - Diesel direction injection and preglow system EDC 17, 01 - Engine electronics functions, Adaption, Oil pressure for engine operation.
43. Follow further instructions displayed on .

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