Table of contents: Removal the turbocharger ↓ Install ↓
Turbocharger 1. Lip seal, replace; 2. Connecting pipe, 40 Nm; 3. Return oil line, to the cylinder block, tighten the union nut with a torque of 20 Nm; 4. Bolt, 15 Nm, grade 10.9 bolts; 5. Gasket, replace; 6. Bolt, 20 Nm; 7. Gasket, replace; 8. Nut, 23 Nm, replace; 9. Diesel particulate filter with catalytic converter; 10. Exhaust gas temperature sensor 1 "G235"; 11. Lip seal, replace; 12. Connecting pipe, 30 Nm; 13. Bolt, 10 Nm; 14. Oil supply line, tighten union nuts to 22 Nm; 15. Turbocharger; 16. Nut, 25 Nm, bolted connection of turbocharger to exhaust manifold, replace, lubricate with heat-resistant paste; 17. Vacuum hose, turbo boost pressure limiting solenoid valve "N75"; 18. Hose clamp, 3.5 Nm; 19. Engine crankcase ventilation hose; 20. Air duct hose; 21. Hose clamp, 3.5 Nm; 22. Gasket, replacement if damaged or leaking; 23. Support; 24. Bolt, 40 Nm; 25. Bolt, 10 Nm; 26. Branch pipe; 27. Air duct to intercooler; 28. Hose clamp, 3.5 Nm
Removal the turbocharger
If the turbocharger has mechanical damage (for example, damage to the impeller), it is not enough to simply replace the turbocharger. To prevent further damage, it is necessary to perform the following work: Check the air filter housing and filter element, as well as the air supply hoses for contamination. Check the entire boost air supply system and intercooler for foreign objects. If foreign objects are found in the boost air system, clean the boost air supply lines and replace the intercooler if necessary. Remove the engine casing "arrows". Remove the air filter housing. Move and release the engine crankcase ventilation. Loosen the hose clamp "2", remove and take out the air duct hose. Remove the sound insulation. Remove the exhaust pipe.
Disconnect bolt connection "1", unscrew bolt "2" and remove the diesel particulate filter suspension mount.
Disconnect the hose clamp "arrow", remove the air duct hose and set it aside.
Unscrew bolts "1" and "2", remove the support.
Unscrew bolts "1" and union nut "2", remove the oil drain line. Disconnect electrical connector "3" of exhaust gas temperature sensor 1 "G235" and disconnect from the bottom of the cylinder block.
Remove vacuum hose "1". Unscrew bolts "2" and "4".
Do not unscrew lines "1" and "2". Unscrew the "arrow" bolts and tie up the EGR cooler.
Unscrew nuts "1...3" on the turbocharger. In a car with an independent heater, nut "1" is accessible from below.
Unscrew the union nut "1". Remove the vacuum hose "2". Disconnect the electrical connector "3" of the boost pressure regulator position sensor "G581". Unscrew the nut "4" securing the turbocharger to the exhaust manifold.
Disconnect the electrical wire on the engine block "arrow".
Unscrew nuts "1" and remove the turbocharger. To prevent dirt from entering, close open lines and pipes on the turbocharger with clean plugs or protective caps. To avoid damage, the removed turbocharger must not be placed on top of the oil return line.
Install
Install in reverse order. Observe the following: Replace gaskets, O-rings and O-rings. When installing, install all heat-insulating sleeves in their original positions. Fill the turbocharger with oil through the oil supply line nipple. The hoses and hose nipples of the air-supply system must be cleaned of oil and grease before installation. To ensure that the air-supply hoses are securely fastened to the nipples, treat the threaded connections of the already used clamps with a rust remover. To ensure that oil is supplied to the turbocharger, run the engine for about 1 minute at idle speed after installing the turbocharger; do not give the engine high revs.
(A link to the original source is available on the website: Audimanual.ru)