coolant AUDI A4 1997 B5 / 1.G AWM Engine Charge Pressure System With Exhaust Turbocharger Workshop Manual

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

21-55


- 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.
Pa
ge 12 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

21-56


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.
Pa
ge 13 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

21-57

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
Pa
ge 14 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

21-58

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
Pa
ge 16 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

21-59

Component
Nm
Turbocharger bracket to cylinder block 25
Turbocharger bracket to turbocharger 30
Catalytic converter to exhaust
turbocharger 30
Oil return line to turbocharger 10
Oil supply line to turbocharger 23
Bracket for oil feed line to cylinder head 23
Heat shield to line for secondary air inlet
3.5
Hose clamps for coolant hoses 2
Hose clamps for air duct hoses 3.5
Pa
ge 18 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