bolt AUDI A6 1996 C5 / 2.G AEB ATW Engines Turbocharger System Workshop Manual

21-24


Turbocharger, removing, installing and
overview

Part I
1 -
Bolt with collar
40 Nm (30 ft lb)Only use genuine equipment bolts parts
catalog
2 -
Gasket
Always replace
3 -
Three Way Catalytic Converter (TWC)
4 -
Nut Always replace30 Nm (22 ft lb)
5 -
Connection 30 Nm (22 ft lb)
6 -
Connection 35 Nm (26 ft lb)
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21-25


CAUTION!
Part numbers are listed here for reference only.
Always check with your Parts department for
the latest information. 7 -
Bolt
20 Nm (15 ft lb)
8 -
Oil supply line Tightening torque for union nut: 25 Nm (18
ft lb) From oil filter bracket item - 1 -, page
Page 17
-6
9 -
Heat shield
10 -
Exhaust manifold
11 -
Bolt
Always replace35 Nm (26 ft lb)Coat thread and bolt head seating surface
with "G 052 112 A3" hot bolt paste.
12 -
Bolt 10 Nm (7 ft lb)
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13 -
Gasket
Always replaceNote installed position
14 -
Coolant return line Union nut tightening torque: 30 Nm (22 ft
lb)
15 -
Nut Always replace25 Nm (18 ft lb)
16 -
Gasket Always replaceNote installed position
17 -
Banjo bolt 25 Nm (18 ft lb)
18 -
Coolant supply line
19 -
Fuse
20 -
Vacuum diaphragm For wastegate
21 -
Bolt 10 Nm (7 ft lb)
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22 -
Bolt
10 Nm (7 ft lb)Install with D 000 600
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23 -
Gasket
Always replace
24 -
Oil return line To oil pan
25 -
Gasket Always replace
26 -
Bolt 10 Nm (7 ft lb)
27 -
Bolt 10 Nm (7 ft lb)
28 -
Nuts 10 Nm (7 ft lb)Install with D 000 600Do not change adjustment
29 -
Turbocharger Check Page 21
-5
30 -
Bolt
45 Nm (33 ft lb)
31 -
Bracket
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Part II
1 -
Vacuum hose
To intake manifold
2 -
Charge pressure bypass valve Check Page 21
-4
3 -
Hose
To charge pressure bypass valve
4 -
Intake air duct To connection at turbocharger
5 -
Hose To Evaporative Emissions (EVAP) purge
regulator valve
6 -
Line To crankcase ventilation
7 -
Socket-head bolt 10 Nm (7 ft lb)
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21-30

Turbocharger, removing and installing


Note:
Replace gaskets and self-locking nuts.

Removing

WARNING!
Do NOT open A/C refrigerant circuit. - Remove noise insulation panel (arrows).
- Unbolt A/C compressor.

- Unbolt turbocharger bracket -2-.
- Disconnect oil return line -1- at turbocharger and lay aside.
- Remove air guide ducts -4- and -5- at turbocharger.
- Remove pressure line banjo fitting -3-.
- Disconnect hose from support for charge air pressure regulation valve
vacuum diaphragm.
- Unbolt bracket for coolant supply line at charge air pressure regulation
valve vacuum diaphragm.
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- Remove intake air duct between cowl and air
cleaner housing.

- Remove air cleaner housing cover.

- Remove the following lines/harness connectors:
1 - At wastegate bypass regulator valve -N75-
2 - At Evaporative Emissions (EVAP) purge regulator valve -N80-
3 - At power output stage -N122-
4 - At Mass Air Flow (MAF) sensor -G70-
- Remove hose connections and remove air cleaner housing (arrows).
- Remove engine covers.

- Unbolt crankcase ventilation hose -1- at cylinder head cover and heat
shield.
- Unbolt both oil supply line bolts -3-.
- Remove heat shield -4-.
- Remove sleeve -2- from coolant return hose.
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- Remove coolant return hose at line to
turbocharger. Line remains bolted to
turbocharger.

- Unbolt oil supply line -7- at turbocharger.

Note:
The exhaust flexpipe must not be bent more than
10 , otherwise it may be damaged.
- Unbolt Three Way Catalytic Converter (TWC)
from turbocharger -6-.

- Unbolt turbocharger from exhaust manifold -5-
.

- Move turbocharger to side and remove coolant
supply line banjo fitting.

- Remove turbocharger.

Installing
Installation is the reverse of removal, noting the
following:

- Perform the following steps before tightening
turbocharger:
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- Loosely bolt coolant supply line to vacuum
diaphragm for charge air pressure regulation
valve.

- Tighten banjo fitting, then tighten mounting
bolt for bracket to proper torque.
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