AUDI A4 1998 B5 / 1.G APB Engine Charge Air System With Turbocharger Workshop Manual

21-1


Charge air system with
turbocharger

Turbocharger, removing and installing

Observe rules for cleanliness Page 21
-8 .

Notes:

Turbochargers must be replaced in pairs.
Manufacturing tolerances may prevent matched
operation.
All hose connections are secured with clips.
Charge air system must be free of leaks.
Replace self-locking nuts.
Replace all seals and gaskets

- Remove engine Page 10
-1 .

Removing right-hand turbocharger

- Remove cover panel from right-hand cylinder head cover -arrows-.
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21-2


Note:
Plug lower section of intake line. - Disconnect hose -1-.
- Disconnect hose -2-.
- Unbolt upper section of intake line -3-.

- Remove lower section of intake line -arrow-.
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21-3


- Push back heat insulation hose in direction of arrow.
- Disconnect vacuum hose -1-.
- Unbolt bracket -2- with gearbox oil lines.
- Disconnect line -3-.
- Disconnect pressure hose -4- from turbocharger.

- Disconnect oil return line -1-.
- Disconnect water line -2-.
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21-4


- Disconnect hose -arrow- from cylinder head.

Installing
Notes:
When installing turbocharger, ensure that O-ring for oil return is not
damaged. - Remove turbocharger -arrows-.
- Install in reverse sequence.
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21-5

Removing left-hand turbocharger

- Push back heat insulation hose in direction of arrow.
- Disconnect vacuum hose -1-.
- Remove lower section of pressure line -2-.
- Disconnect pressure hose -3- from turbocharger.

- Disconnect vacuum line -1-.
- Disconnect vacuum hose -2-.
- Disconnect line -3- going to right-hand turbocharger.
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21-6


Installing
Notes:
When installing turbocharger, be sure that o-ring at connection flange for
oil return is not damaged. - Disconnect oil return line -1-.
- Disconnect water line -2-.
- Remove turbocharger -3- (3 bolts).
- Installation is the reverse of removal.

The text "Abgasturbocharger" must be readable as shown in illustration,
install turbocharger hose -1- properly if necessary.
The hose clamps -2- must be installed as shown in illustration. The bolt-
locks on the screw clamps must be placed at the X-marking on the hose.
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21-7

Tightening torque

Bolted mountings Tightening
torque
Turbocharger 20 Nm
Intake line to cylinder head 10 Nm
Heat shield to turbocharger 10 Nm
Exhaust manifold to exhaust
pipe 25 Nm
Injector pipes 30 Nm
Intake pipe to engine
support 10 Nm
Oil pipe to turbocharger 15 Nm
Oil pipe to intake manifold 20 Nm
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21-8

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 parts that have been removed on a clean
surface and cover. Do not use fluffy cloths!
Carefully cover opened components or seal, if
the repair cannot be carried out immediately.
Only install clean components: Only unpack
replacement parts 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.
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21-9

Turbocharger and charge pressure
regulating valve, checking


Safety notes
Note the following points if test equipment has to
be used during a road test:

WARNING!

Test equipment must always be secured on
the rear seat and operated from there by a
second person.
If test equipment is operated from the front
passenger seat, the occupant could be
injured by the passenger's airbag in an
accident.

Special tools, testers and auxiliary items
Turbocharger tester VAG 1397 A
VAG 1551 Scan Tool or VAG 1552 with cable
VAG 1551/3
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21-10

Requirements for test:

Diagnostic Trouble Code (DTC) memory has
been interrogated

Repair Manual, 2.7 Liter V6 5V BiTurbo Fuel
Injection & Ignition, Engine Code(s): APB, Repair Group 01


Output Diagnostic Test Mode (DTM) has
been performed
Engine oil temperature at least 60 C

All vacuum connections airtight

- Loosen bolts -arrows- and remove engine cover panel -B-.
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