Removing and installing turbocharger - vehicles with front-wheel drive -engine code AXR- — AUDI

ATD AXR
Special tools and workshop equipment required

VAS 5024 A

Removing

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

Disconnect hose -arrow- at vacuum unit for boost pressure control.

Disconnect hose -4- to air cleaner housing.
Disconnect crankcase vent pipe -5- from air duct hose.
Release spring clamp on turbocharger using VAS 5024 A.
Set aside the vacuum hoses.
Unscrew bolts -1- and -2- and remove air duct pipe -3-.

Unscrew oil feed line at oil filter bracket -arrow- and also at coolant pipe.

Remove air duct pipe from right longitudinal member -arrows-.

Remove centre and right noise -arrows-.

Unbolt heat shield for right drive shaft -arrows-.
Detach right drive shaft from gearbox flange.

Unbolt bracket for exhaust system from assembly mounting
-arrows-.

Note:

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

Unscrew securing bolts -arrows- of front exhaust pipe/turbocharger.

Detach the exhaust system at the clamping sleeve -arrows-.
Remove the front exhaust pipe.

Unscrew pendulum support from subframe -arrows A-.

Detach air duct hose -4-.
Remove bolts -2- and -3- and detach bracket for turbocharger.
Remove oil return pipe -1- at cylinder block.

Remove connection pipe for exhaust gas recirculation -arrows-.

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

Remove heat shield from exhaust manifold -arrows-.

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

Installing

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

Notes:

Always 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 exhaust system and align it stress-free => Page 26-13.
Install right drive shaft.

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

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 turbocharger · 22
Connection pipe for exhaust gas recirculation to · / changeover / valve · / 22
exhaust / manifold · 22
Turbocharger bracket to cylinder block · / 40
Turbocharger bracket to turbocharger · 20
Oil return line to cylinder block · 30
Drive shaft heat shield to cylinder block · 35
Oil supply pipe to oil filter bracket · 25
Pendulum support to subframe · 20 + 90°2)3)

1)
Replace the nuts.

2)
Stretch bolts, replace

3)
90°corresponds to a quarter of a turn