Table of contents: Removal ↓ Installation ↓
Removal
Remove the engine hood. Remove the engine cover. Remove the noise insulation screen located below by disconnecting the crankcase ventilation hose. Using a screwdriver, remove caps "3" and "4" from the windshield wiper arms. Unscrew the nuts on both arms a few turns. Release arms "1" and "2" by slightly tilting them on the windshield wiper axles. Unscrew the nuts completely and remove the windshield wiper arms.
Disconnect the windshield washer fluid tube "3". Disconnect the plug connectors "4" and "5" of the heated washer nozzles. Release the hose clamp "6" using hose clamp pliers "V.A.G 1921" remove the drain hose from the fairing grille. Remove the rubber seal "1" of the fairing grille. Remove the fairing grille "2".
Unscrew the bolts and nuts of the "arrows". Remove the fresh air intake duct and hang it on the right side of the car.
Disconnect plug connector "2" of air flow meter "G70". Disconnect vacuum hose "1". Release hose clamp "4" and remove air duct with air flow meter "G70". Unscrew nut "3".
Remove the air hose "2" connecting the intercooler and the intake manifold. Ignore item "1".
Disconnect vacuum hose "1" from mechanical recirculation valve 0G. Remove vacuum hose "2" from throttle control valve "N₂11".
Warning! The temperature of the fuel lines or fuel in vehicles equipped with a unit injector engine can reach 100°C. Allow the fuel to cool before disconnecting the fuel lines, otherwise severe burns may occur.
Mark and disconnect the fuel pressure line "2" and the fuel return line "1".
Unscrew the "arrow" bolts and remove the air duct from the turbocharger.
Unscrew bolts "2" on the pre-catalyst bracket. Ignore item "1".
Loosen the nuts of the "arrow" threaded connection of the pre-catalyst with the turbocharger.
Instructions: The detachable element between the pre-catalyst and main catalyst must not be bent more than 10°. Risk of damage!
Disconnect the pre-catalyst from the turbocharger. Tie the pre-catalyst to the body.
Clamp the coolant hoses leading to the EGR radiator using hose clamps "3094". Remove the coolant hoses "arrows" from the EGR radiator.
Unscrew bolts "2" and "3", as well as nuts "1", and remove the EGR radiator.
Unscrew the "arrow" bolts and remove the intake manifold.
Remove the air hose "1" from the turbocharger. Unscrew the pressure oil line "2" from the turbocharger. Unscrew the 3 nuts "3" of the turbocharger.
Remove the vacuum hose "2" from the vacuum boost pressure regulator and release it. Remove the oil return line "3" from the cylinder block. Unscrew the support "1" of the turbocharger from the cylinder block. Remove the turbocharger upwards.
Installation
Installation is in the reverse order, replacing the gaskets, cuffs and self-locking nuts. Fill the turbocharger with oil through the connecting pipe of the pressure oil line. The supercharging system must be sealed. The hoses and pipes of the air supercharging system must be cleaned before installing oils and grease. Use clamps of the appropriate series to secure all hose connections. Install the intake manifold. Install the primary main catalytic converter. Install and adjust the windshield wiper arms. Check the oil level.
Instructions: After installing the turbocharger, leave the engine to idle (do not increase the speed for 1 minute to ensure that oil is supplied to the turbocharger.
Tightening torques:
- Turbocharger to exhaust manifold: 25 Nm 1)
- Turbocharger support to cylinder block: 20 Nm
- Cylinder block oil return line: 30 Nm
- Pressure oil line to turbocharger: 22 Nm
- Intake manifold to cylinder head: 25 Nm
- EGR cooler to mechanical EGR valve: 25 Nm
- EGR cooler to intake manifold: 25
- EGR cooler to exhaust manifold: 25
- Air duct to turbocharger: 8 Nm
1) Replace the nuts.
(The article was copied from the website AUDImanual.ru)