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

ATD AXR
Removing

Remove oil dipstick -1- from guide tube.
Remove engine cover -arrows-.
Reinsert dipstick in guide tube.

Remove air duct hose -1- from air duct pipe.
Detach connector of air mass meter -3-.
Unscrew bolts -4- and -5-.
Remove vent hose -2- off air cleaner housing.
Remove air cleaner housing.

Remove intake manifold => Page 15-64.

Unscrew nuts -2-, -4- and -5-.

Note:

The front exhaust pipe -1- remains connected to the turbocharger -3-.

Note:

The isolating element in front exhaust pipe must not be deflected more than 10°to avoid damage.

Remove bolts -arrows- at the front exhaust pipe/catalytic converter flange.

Detach the exhaust system at the clamping sleeve -arrows-.
Remove catalytic converter.

Unbolt bracket for exhaust system from assembly mounting
-arrows-.
Press front exhaust pipe off turbocharger.

Detach right drive shaft from gearbox flange.
Remove bolts -1- and -2- and remove bracket for turbocharger.
Remove oil return pipe -3- at cylinder block.

Remove bolts -arrows- and remove resonator -1-.

Unscrew oil feed line from turbocharger and exhaust manifold
-arrows-.

Unscrew oil feed line from oil filter bracket -arrow- and also on coolant pipe and lay line to one side.

Remove upper toothed belt guard.
Remove heat shield from exhaust manifold -arrows-.

Unscrew nuts -arrows-.
Remove packing plates.
Remove exhaust manifold/turbocharger upwards.

Installing

Installation is carried out in the reverse order; note the following:

Notes:

Replace seals, gaskets and self-locking nuts.
Note installation position of exhaust manifold/turbocharger gaskets.
Fill the turbocharger with engine oil via the oil supply connection.
Hose connections and hoses for charge air system must be free of oil and grease before assembly.
Secure all hose connections with the correct hose clamps (same as original equipment):

=> Parts List

Install right drive shaft.

=> Running Gear, FWD and 4WD; Repair group 40
Running Gear, FWD and 4WD

Install intake manifold => Page 15-68.
Install exhaust system and align it stress-free => Page 26-35.

When installing air duct pipes with connectors, ensure that the securing clip -arrow- engages audibly in the retaining lug -A-.
Check oil level => Page 17-23.

Note:

After installing the turbocharger, run engine for approx. 1 minute at idling speed; do not rev. up immediately. This ensures the turbocharger is properly lubricated.

Tightening torques

Component · Nm
Exhaust manifold/turbocharger to cylinder head · 25 1)
Heat shield to exhaust manifold/turbocharger · 20 1)
Oil supply pipe to oil filter bracket · 25
Oil supply pipe to turbocharger · 22
Turbocharger bracket to cylinder block · 40

1)
Replace the nuts.

Component · Nm
Turbocharger bracket to turbocharger · 20
Oil return line to cylinder block · 30