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

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CAUTION!
The air conditioner refrigerant circuit must not be opened. - Loosen bolts securing ribbed belt tensioning roller for A/C compressor -
arrows-. Loosen belt and remove.
- Disconnect A/C compressor from bracket and secure to body with wire.

- Remove bracket for exhaust turbocharger -2-.
- Unscrew oil return line -1- from exhaust turbocharger and set aside.
- Loosen air duct hoses -4- and -5- on exhaust turbocharger.
- Remove banjo bolt -3- for pressure line.
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- Remove engine cover -arrows-.

- Remove air filter cover -arrow-.
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- Remove bolts -arrows-.
- Remove air duct -1- and -2-.

- Disconnect wiring connectors as follows:
1 - on ACF valve (in addition, remove ACF valve from air filter housing)
2 - on mass air flow sensor
3 - on Wastegate Bypass Regulator valve -N75-
- Move wiring aside and remove air filter housing -arrows-.
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- Remove secondary air inlet line by disconnecting hoses -arrows- and
removing bolts -1-.
- Remove right-hand heat shield on cylinder head.
- Remove hose of vacuum unit for wastegate bypass regulator valve -
N75- on exhaust turbocharger.
- Unbutton sleeve on coolant return hose.

- Clamp coolant return hose to exhaust turbocharger with hose clamp
3094.
- Loosen hose clamp -4- and remove coolant return hose from exhaust
turbocharger line.
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Note:
The isolating element in the exhaust system must not be bent more than
10 or it may be damaged. - Loosen bolts -1- and -3- of oil feed line.
- Remove oil feed line -5- at exhaust turbocharger.- Remove catalytic converter from exhaust turbocharger -6-.
- Remove exhaust turbocharger from exhaust manifold -2-.
- Swivel exhaust turbocharger to side, loosen mounting angle and banjo
bolt of coolant feed line on exhaust turbocharger.
- Remove exhaust turbocharger.
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Installing
Installation is carried out in the reverse order of
removal; note the following:

Note:

All cable ties which are released or cut open
when removing must be installed in the same
position when installing.
Secure all hose connections with the correct
hose clips (same as original equipment):

Parts Catalog

The hose connectors and hoses must be free of
oil and grease before assembling.
Always replace seals, gaskets and self-locking
nuts.

- Perform following operating steps before
tightening exhaust turbocharger:

-
Fasten coolant feed line loosely to bracket on
vacuum unit for wastegate bypass regulator
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valve.

- Tighten banjo bolt to 35 Nm and then tighten
securing bolt of bracket to 10 Nm.
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Note:
Fill the exhaust turbocharger with engine oil via
the oil supply connection.

- Install ribbed belt for A/C compressor Page
13
-20
.

- Top up coolant Page 19
-7 .

- Check oil level Page 17
-35
.

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
Coolant feed line to exhaust turbocharger
35
Bracket for coolant feed line to exhaust
turbocharger
10
Turbocharger to exhaust manifold
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