AUDI A4 1999 B5 / 1.G AWM Engine Charge Pressure System With Exhaust Turbocharger User Guide
Manufacturer: AUDI, Model Year: 1999,
Model line: A4,
Model: AUDI A4 1999 B5 / 1.G
Pages: 22, PDF Size: 0.46 MB
AUDI A4 1999 B5 / 1.G AWM Engine Charge Pressure System With Exhaust Turbocharger User Guide
A4 1999 B5 / 1.G
AUDI
AUDI
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AUDI A4 1999 B5 / 1.G AWM Engine Charge Pressure System With Exhaust Turbocharger User Guide
Trending: service, oil pressure, belt, check engine, air condition, wiring, oil
Page 11 of 22
21-54
- 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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Page 12 of 22
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.
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Page 13 of 22
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.
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Page 14 of 22
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
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Page 15 of 22
valve.
- Tighten banjo bolt to 35 Nm and then tighten
securing bolt of bracket to 10 Nm.
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Page 16 of 22
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
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Page 17 of 22
35
1)
2)
1) Replace bolts
2) Coat thread and head attachment area with
high temperature lubricant G 052 112 A3
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Page 18 of 22
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
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Page 19 of 22
21-60
Charge air cooling system components,
removing and installing
Note:
Parts Catalog
Secure all hose connections with the correct
hose clips (same as original equipment): Before a check or repair all hoses and lines
must be checked for correct seating and leaks.
1 -
Air duct
2 -
Rubber grommet
3 -
Hose
Between charge air cooler and air ducting
in front apron
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Page 20 of 22
21-61
4 -
Air duct hose
Between intake manifold and charge air
cooler (intercooler)
5 -
O-ring Replace, if damaged
6 -
Charge Air Pressure sensor -G31-
7 -
3 Nm
8 -
Rubber grommet
9 -
Bracket Riveted to body
10 -
Rubber grommet
11 -
Charge air cooler Removing and installing Page 21
-62
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Trending: low oil pressure, belt, cooling, ABS, torque, oil temperature, checking oil