1997 AUDI A4 AWM Engine Charge Pressure System With Exhaust Turbocharger Workshop Manual

21-44


Charge pressure system with
exhaust turbocharger,
servicing

Rules for cleanliness

When working on the exhaust gas turbocharger,
pay careful attention to the following 5 rules:

Thoroughly clean all unions and the adjacent
areas before disconnecting.
Place removed parts on a clean surface and
cover. Use lint-free cloths.
Carefully cover or seal open components if
repairs cannot be carried out immediately.
Only install clean components: Only remove
replacement parts from packaging immediately
prior to installation. Do not use parts that have
been stored loose (e.g. in tool boxes etc.).
When the system is open: Do not work with
compressed air if this can be avoided. Do not
move vehicle unless absolutely necessary.
Pa
ge 1 of 22 Char
ge pressure s
ystem with exhaust turbochar
ger, servicin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE06.21.3

21-45


Turbocharger, removing and installing -
Overview

Part I
Parts Catalog 1 -
30 Nm
Only use original bolt
2 -
Gasket
Always replace
3 -
Catalytic converter
4 -
30 Nm Always replace
5 -
30 Nm
6 -
35 Nm
Pa
ge 2 of 22 Char
ge pressure s
ystem with exhaust turbochar
ger, servicin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE06.21.3

21-46


7 -
Oil supply line
Tighten union nut to 23 NmFrom oil filter bracket -Item 24 -, Page 17
-10

8 -
3.5 Nm
9 -
Heat shield
10 -
23 Nm
11 -
Exhaust manifold
Removing and installing Page 26
-21
12 -
35 Nm
Always replaceCoat thread and head attachment area with
high temperature lubricant G 052 112 A3
13 -
10 Nm
Pa
ge 3 of 22 Char
ge pressure s
ystem with exhaust turbochar
ger, servicin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE06.21.3

21-47


14 -
Banjo bolt - 30 Nm
15 -
Gasket
Always replaceNote installation position
16 -
Coolant return line Tighten union nut to 30 Nm
17 -
30 Nm Always replace
18 -
Gasket Always replaceNote installation position
19 -
Banjo bolt - 35 Nm
20 -
Coolant supply hose/line
21 -
Banjo bolt - 35 Nm Apply D 000 600 when installing
Pa
ge 4 of 22 Char
ge pressure s
ystem with exhaust turbochar
ger, servicin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE06.21.3

21-48


22 -
10 Nm
Apply D 000 600 when installing
23 -
Gasket Always replace
24 -
Oil return line To oil pan
25 -
Gasket Always replace
26 -
10 Nm
27 -
10 Nm
28 -
Turbocharger Checking Page 21
-8
29 -
25 Nm
30 -
Bracket
Pa
ge 5 of 22 Char
ge pressure s
ystem with exhaust turbochar
ger, servicin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE06.21.3

21-49


Part II
1 -
Vacuum hose
To Recirculatiing valve for turbocharger -
N249-
2 -
Recirculating valve Checking Page 21
-24
3 -
Hose
To recirculating valve
4 -
Air duct hose To connection on turbocharger
5 -
Hose To ACF valve
6 -
line To crankcase vent
7 -
10 Nm
Pa
ge 6 of 22 Char
ge pressure s
ystem with exhaust turbochar
ger, servicin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE06.21.3

21-50


8 -
Hose
To crankcase breather line
9 -
Pressure regulating valve For crankcase breather
10 -
Hose To turbocharger
11 -
Hose To vacuum unit for charge pressure
regulating valve
12 -
Wastegate Bypass Regulator valve -N75-
13 -
Angled connector
14 -
Hose To turbocharger
Pa
ge 7 of 22 Char
ge pressure s
ystem with exhaust turbochar
ger, servicin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE06.21.3

21-51

Turbocharger, removing and installing


Special tools and equipment

Removing
Hose clamps 3094

- Remove sound insulation -arrows-.
Pa
ge 8 of 22 Char
ge pressure s
ystem with exhaust turbochar
ger, servicin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE06.21.3