Removing and installing turbocharger - vehicles with four-wheel drive — AUDI

🧭 Before you start

Fits: Audi A3 (8P, 2003–2012)

• Renewed: charge air cooler, gaskets

Don't miss

• Disregard (items 1, 2, 5 and 6).
• Disregard (item 2).
• When slackening the flange bolt securing the drive shaft, the wheel bearing must not be under load (vehicle must not be standing on its wheels). — Unscrew flange bolt (2) from drive shaft (right-side) (1).
• To avoid damage, the flexible joints in the front exhaust pipe must not be bent more than 10°.
• 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

📋 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 intake 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.Observe rules for cleanliness when working on turbocharger — Remove particulate filter .
2. Unplug electrical connector (3) and move wiring clear. [Note: Disregard (items 1, 2, 5 and 6).]
3. Lift off engine cover panel (outside (1) and inside (2)) by pulling up evenly.
4. Unplug electrical connector (5) for temperature sender before particulate filter G506 and move wiring clear.
5. Pull cover off air duct (release clips on sides) (arrows).

6. Unclip air duct at the bottom by releasing clips (arrows).
7. Detach air duct (bottom) together with air hose.
8. Unplug electrical connector (1) at air mass meter G70.
9. Detach vent hose (3) and air hose (2).
10. Unscrew bolt (4) and remove air cleaner housing.
11. Remove crankcase breather hose (2).
12. Move vent hose (4) and vacuum hoses (3) clear at air intake hose.
13. Slacken hose clip (1).
14. Swing air hose to rear and detach from turbocharger.
15. Remove bolt (arrow) at front of air pipe.
16. Remove bolt (1).
17. Disconnect oil supply hose (3) from turbocharger.
18. Pull retaining clips (arrows) out slightly and detach air intake hose. [Note: Disregard (item 2).]
19. Unscrew nuts (1) and remove heat shield from exhaust manifold (left-side).
20. Remove nuts (2) and bolts (3) and remove connecting pipe for exhaust gas recirculation.
21. Remove flange shaft (right-side) 39.
22. Move wiring for exhaust gas temperature sender 1G235(item 1) clear.
23. Unscrew bolts (arrows) and remove heat shield.
24. Remove front right wheel.
25. Remove centre noise insulation (fasteners 1 ... 3).
26. Remove noise insulation (right-side) (fasteners 1 ... 3).
27. ⚠ When slackening the flange bolt securing the drive shaft, the wheel bearing must not be under load (vehicle must not be standing on its wheels). — Unscrew flange bolt (2) from drive shaft (right-side) (1).
28. Unplug electrical connector (1) at oil level and oil temperature sender G266.
29. Unclip bracket (2) from subframe.
30. Unbolt heat shield for drive shaft (right-side) (arrows).
31. Unbolt drive shaft (right-side) from gearbox flange.
32. Push drive shaft (right-side) towards front of vehicle.
33. Unscrew bolts (1 ... 3) and remove pendulum support.
34. Unscrew temperature sender after particulate filter G527(item 1) from exhaust pipe behind particulate filter.
35. Unscrew pressure pipe (2) going to exhaust gas pressure sensor 1G450.
36. Remove nuts (1) and (3) and bolt (2) and detach bracket for particulate filter.
37. Remove front cross-piece for underbody (arrows). [Note: To avoid damage, the flexible joints in the front exhaust pipe must not be bent more than 10°.]
38. Loosen nuts on clamp (1).
39. Remove particulate filter by rotating clockwise through 180°.
40. Remove drive shaft (right-side) through wheel housing.
41. Unscrew nuts (1) and remove heat shield from exhaust manifold (left-side).
42. Remove nuts (2) and bolts (3) and remove connecting pipe for exhaust gas recirculation.
43. Remove bolts (1), (2) and banjo bolt (3).
44. Remove support for turbocharger together with oil return pipe.
45. Remove bolts (arrows).
46. Remove turbocharger with exhaust manifold from below and guide out to the right by pushing engine/gearbox assembly slightly forwards. [Note: Renew gaskets, seals and self-locking nuts.Fill turbocharger with engine oil at connection for oil supply pipe.Secure all hose connections with the correct type of hose clips (same as original equipment) Electronic parts catalogue.]
47. Install particulate filter .
48. Install flange shaft (right-side) 39.
49. Install exhaust system and align it free of stress .
50. Adhere to the instructions for installing air pipes and hoses with plug-in connectors .
51. 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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