Removing and installing turbocharger - vehicles with engine code letters AJM — AUDI

🧭 Before you start

Fits: Audi A6 C5 (4B)

• Renewed: seals

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• Before removing, mark direction of rotation of poly V-belt with chalk or felt-tipped pen. If the belt runs in the opposite direction when it is refitted, this can cause breakage.
• Refrigerant circuit of air conditioner must not be opened. — Unbolt air conditioner compressor from bracket.
• After installing turbocharger, allow engine to idle for approx. 1 minute and do not rev up immediately to ensure turbocharger is supplied with oil.

🔧 Engine codes this applies to

📐 49 workshop diagrams for AJM

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

📋 Procedure

1. Vehicles with auxiliary heater: remove bolts (arrows) securing exhaust pipe for auxiliary/additional heater to noise insulation.
2. Release quick-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-tipped 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. ⚠ Refrigerant circuit of air conditioner must not be opened. — Unbolt air conditioner compressor from bracket.

6. Tie up air conditioner compressor to vehicle, with lines attached.
7. Disconnect air intake hose from turbocharger (bottom) (arrows).
8. Remove bolt (1) from noise insulation cover above drive shaft (right-side).
9. Disengage hook (2) and detach noise insulation.
10. Remove bracket for turbocharger (arrows).
11. Detach oil return pipe at cylinder block (arrow).
12. Unscrew turbocharger/exhaust manifold securing nut (accessible from below).
13. Pull dipstick (1) out of guide tube.
14. Unclip cover caps.
15. Unfasten nuts (arrows) and detach engine cover.
16. Remove insulation beneath cover.
17. Re-insert dipstick in guide tube.
18. Unclip cover caps.
19. Unscrew bolts (arrows) and remove air cleaner cover.
20. Unscrew bolts (arrows).
21. Remove air ducts (1) and (2).
22. Disconnect breather hose (2) from air cleaner housing.
23. Unplug electrical connector (4) at air mass meter G70.
24. Detach EGR valve N18(Item 3) from air cleaner housing.
25. Move wiring harness going to air cleaner clear (arrow).
26. Loosen hose clip (5) to remove air intake hose.
27. Unscrew bolt (1) and remove air cleaner housing.
28. Disconnect air intake hose from turbocharger (arrows).
29. Remove connecting pipe for exhaust gas recirculation (arrows).
30. Detach heat shield from exhaust manifold (arrows).
31. Remove oil supply pipe bracket from exhaust manifold.
32. Pull hose (2) off vacuum unit for charge pressure control.
33. Unscrew bolt (1) from bracket for oil supply pipe.
34. Unscrew oil supply pipe (3) at turbocharger.
35. Unscrew nuts securing turbocharger to front exhaust pipe (arrows).
36. Unscrew top turbocharger securing nuts.
37. 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 pipe.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.Fit all cable ties in the original position when installing.Secure all hose connections with the correct type of hose clips (same as original equipment) Parts catalogue.]
38. Install exhaust system and align it free of stress .
39. Install poly V-belt .
40. Check oil level . [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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