Audi TT (2007 year). Manual — part 52
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
21 - Pipe
❑ To exhaust gas recirculation cooler
22 - Exhaust gas temperature sender 1 -G235-
23 - Bolt
❑ 20 Nm
24 - Support
❑ For turbocharger
25 - O-rings
❑ Renew
1.3
Removing and installing turbocharger
Special tools and workshop equipment required
♦ Hose clip pliers -VAS 6340-
Removing
Caution
If the turbocharger has suffered mechanical damage (e.g.
damaged compressor wheel), it is not sufficient merely to fit a
new turbocharger. The following work must be performed in
order to avoid further damage:
♦ Check air cleaner housing, air filter element and air intake
hoses for dirt and foreign particles.
♦ Check the entire charge air system (including the charge
air cooler) for foreign matter.
♦ If foreign matter is found in the charge air system, clean
all relevant ducts and hoses and renew charge air cooler
if necessary.
1. Turbocharger
199
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Press release tabs and disconnect crankcase breather hose
-1- from cylinder head cover.
– Move vacuum hoses -arrows- on air pipe clear.
– Loosen hose clip -2- and detach air pipe.
– Detach heat shield sleeve.
– Detach vacuum hose -2- from vacuum unit of turbocharger.
– Disconnect vacuum hose -3-.
– Unplug electrical connector -1- at position sender for charge
pressure positioner -G581- .
– Unplug electrical connector -1- for exhaust gas temperature
sender 1 -G235- and move electrical wire clear.
Note
Disregard -items 2, 3 and 4-.
– Remove bolts -arrows-.
– Use removal lever -80 - 200- to move electrical wiring and ho‐
ses at air pipe (left-side) clear.
– Release hose clip -3- and push air pipe (left-side) from turbo‐
charger towards the left.
Note
Disregard -items 1, 2, 4 and 5-.
200
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Unscrew oil supply line from connection on turbocharger. To
do so, counterhold at hexagon flats with an open-end spanner
and slacken union nut -3-.
Note
Disregard -items 1, 2-.
– Unscrew nuts -1- and detach heat shield (left-side) from ex‐
haust manifold.
– Remove nuts -2- and bolts -3-, and detach exhaust gas recir‐
culation pipe.
– Remove bolts -1- and detach oil return pipe.
Note
Disregard -items 2, 3-.
– Remove nuts -arrows- and detach turbocharger with exhaust
manifold from cylinder head.
1. Turbocharger
201
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Move clear electrical wiring for exhaust gas temperature send‐
er 1 -G235- -item 1-.
– Remove bolts -arrows- and detach heat shield.
– Take out turbocharger with exhaust manifold from below, at
the same time pushing engine/gearbox assembly slightly for‐
wards.
Installing
• Tightening torques
Installation is carried out in the reverse order; note the following:
Note
♦
Renew seals, gaskets, O-rings and self-locking nuts.
♦
Fill turbocharger with engine oil at connection for oil supply
pipe.
♦
Hose connections and air pipes and hoses must be free of oil
and grease before assembly.
♦
Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Electronic parts catalogue .
♦
To ensure that the air hoses can be properly secured at their
connections, spray rust remover onto the worm thread of used
hose clips before installing.
♦
After installing the turbocharger, allow the engine to idle for
approx. 1 minute without pressing the accelerator to ensure
that the turbocharger is supplied with oil.
♦
Fit heat insulation sleeves in the original positions when in‐
stalling.
– Install air pipe (left-side)
– Check oil level ⇒ Maintenance ; Booklet 810 .
1.4
Renewing vacuum unit with position
sender for charge pressure positioner -
G581-
Special tools and workshop equipment required
♦ Socket -T10422-
♦ Ring spanner -T10423-
♦ Vehicle diagnostic tester
Caution
The tools listed, in particular the socket -T10422- , are only
intended for use according to the procedure described in the
following; do NOT use the tools for other bolted connections.
There is danger of deformation if the specified torques are ex‐
ceeded.
202
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