oil AUDI A6 2000 C5 / 2.G AEB ATW Engines Turbocharger System Workshop Manual

21-6

Test conditions:

Check DTC memory Repair Manual, 1.8
Liter 4-Cyl. 5V Turbo Fuel Injection &
Ignition, Repair Group 01
Perform output diagnostic test mode
(function 03)
Minimum engine oil temperature: 60 C
(140 F)

All vacuum connections are free of leaks

Test procedure

- Using T-fitting, connect VAG1397A turbocharger tester test hose to
front of intake manifold.
- Guide test hose over rear corner of hood through right window opening
into vehicle interior.
Pa
ge 7 of 50 Turbochar
ger s
ystem
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.21.1

21-19

Performing pressure test:

- With outlet hose -1- of VAG 1687 connected to air pressure adapter:
- Attach shop air supply line to previously installed male fitting ( Page
21
-14
.

CAUTION! - Open valve -3- between regulator valve and gauge.
- Adjust test pressure up to 0.5 bar ( CAUTION below) by turning
regulator valve -2-.
DO NOT pressurize the system above 0.5 bar!Doing so may force oil into the intake system which can damage
the engine.
- Slowly open outlet valve -4- (after gauge) to test hose connections.
- Observe pressure gauge for a drop in pressure.
Pa
ge 25 of 50 Turbochar
ger s
ystem
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.21.1

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)
Pa
ge 33 of 50 Turbochar
ger s
ystem
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.21.1

21-27


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
Pa
ge 36 of 50 Turbochar
ger s
ystem
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.21.1

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.
Pa
ge 39 of 50 Turbochar
ger s
ystem
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.21.1

21-31

- 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.
Pa
ge 41 of 50 Turbochar
ger s
ystem
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.21.1

21-32

- 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:
Pa
ge 43 of 50 Turbochar
ger s
ystem
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.21.1

21-33

Note:
Add oil to turbocharger through oil supply line
connection flange.

- Fill up coolant Page 19
-4 .

WARNING!

The cooling system is pressurized when the
engine is warm. When opening the expansion
tank, wear gloves and other appropriate
protection, cover the cap with a cloth and
open carefully to relieve system pressure
slowly.

Note:
After installing the turbocharger, let engine idle
for approx. 1 minute without increasing engine
speed. This ensures adequate oil supply to the
turbocharger.

- Check engine oil level Page 17
-27
.
Pa
ge 45 of 50 Turbochar
ger s
ystem
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.21.1

21-34

Tightening torques

Component
Tightening
torques
Oil return line to turbocharger 10 Nm (7 ft
lb)
Turbocharger bracket to
turbocharger (bolt and washer
assembly M8)
1) 40 Nm (30 ft
lb)
Turbocharger bracket to cylinder
block 45 Nm (33 ft
lb)
Oil feed line to turbocharger 25 Nm (18 ft
lb)
Coolant supply pipe bracket to
turbocharger 10 Nm (7 ft
lb)
Oil supply line bracket to cylinder
head 20 Nm (15 ft
lb)
Coolant supply line to
turbocharger 25 Nm (18 ft
lb)
Crankcase ventilation line to
cylinder head 10 Nm (7 ft
lb)
Coolant return line to
turbocharger 30 Nm (22 ft
lb)
Turbocharger to exhaust
manifold 35 Nm (26 ft
lb)
Three Way Catalytic Converter 30 Nm (22 ft
Pa
ge 46 of 50 Turbochar
ger s
ystem
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.21.1