Removal and installation of a turbocharger. Audi A4 (from 2001 to 2005 release)
Service of Audi A4 from 2001 to 2005 release.
1. Operation and maintenance of the car
2. Engine
2.1. General information
2.2. Predvaritlny checks
2.3. Mekhanichsky part (petrol engines 2,0l)
2.4. Lubrication system
2.5. Cooling system
2.6. System of injection
2.6.1. Removal and installation of a turbocharger
2.6.2. Removal and installation of the vacuum block of a turbocharger
2.6.3. Adjustment of the vacuum block of a turbocharger (the turbocharger is removed)
2.6.4. The general instructions on self-diagnostics of system of injection
2.6.5. Decrease in high pressure of fuel
2.6.6. Removal and installation of a flowmeter of air
2.6.7. Removal and installation of an inlet collector with a fuel stage
2.6.8. Removal and installation of a fuel stage (Rail)
2.6.9. Removal and installation of nozzles
2.6.10. Check of pressure of fuel and residual pressure in front of the pump of high pressure
2.6.11. Check of residual pressure
2.6.12. Removal and installation of the pump of high pressure
2.6.13. Replacement of the control unit of the engine
2.6.14. Removal and installation a lambda probe in front of the catalyst
2.6.15. Removal and installation a lambda probe after the catalyst
2.6.16. The fuel tank (front-wheel cars – all models with MPI engines and 2,0 l of FSI)
2.6.17. Pumping of fuel from a tank
2.6.18. Removal and installation of the fuel tank with hinged details
2.6.19. Electric check of the fuel pump
2.6.20. Check of amount of the fuel given by the fuel pump (cars from the 4th the cylinder engine with a free admission)
2.6.21. Check of amount of the fuel given by the fuel pump (atomobil with the engine of 1,8 l Turbo)
2.6.22. Check of amount of the fuel given by the fuel pump (atomobil from the 4th the cylinder FSI engine)
2.6.23. Check of amount of the fuel given by the fuel pump (cars from 6 the cylinder MPI engine)
2.6.24. Removal and installation of knot of supply of fuel
2.6.25. Fuel tank (all-wheel drive cars till 10:04)
2.6.26. Pumping of fuel from a tank
2.6.27. Removal and installation of knot of a pedal of an accelerator with sensors of provision of a pedal
2.7. System of production of the fulfilled gases
2.8. Mechanical part (petrol engines 3,0; 3,2 l)
2.9. Mechanical part (petrol engines of 4,2 l)
2.10. Mechanical part (diesel engines of 2,0 l)
2.11. Tables
3. Transmission
4. Running gear
5. Steering mechanism
6. Brake system
7. Onboard electric equipment
8. Body
9. Schemes of electric equipment
 







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2.6.1. Removal and installation of a turbocharger

Remove

Fig. 2.54. Engine casing


Remove a casing of the engine (fig. 2.54).
Open a cover of a broad tank of the cooling system.
Merge cooling liquid.

Fig. 2.217. Fastening of the heat-shielding screen


Remove the heat-shielding screen (fig. 2.217).
Turn off a tube of ventilation of a case of the engine from a turbocharger 1.

Fig. 2.218. Turbocharger and tube of ventilation of a case


Disconnect a hose of ventilation of a case of the engine from a cover of GBTs 2 and uncover (fig. 2.218).
Disconnect the highway of an absorber to a turbocharger from GBTs 3 cover.
Turn off the oil giving highway from a turbocharger 4.
Remove the catalyst.
Turn off the giving water hose from a turbocharger.

Fig. 2.44. Bolts of an exhaust pipe of an independent additional heater


In cars with an additional heater unscrew bolts of an exhaust pipe of an independent additional heater from the noise-insulating screen (fig. 2.44).

Fig. 2.45. Fastening of a forward noise isolation


Weaken quick disconnect couplings 1 and 2 and remove a forward noise isolation (fig. 2.45).
Where are available, weaken quick disconnect couplings 3 and remove the back noise-insulating screen.

Fig. 2.51. Air ducts to the intercooler and to a turbocharger


Disconnect вохдуховод 1 to a turbocharger on the right below (fig. 2.51).
Disconnect an air duct to the intercooler from a frame of a radiator 2.

Fig. 2.80. Inlet hose of the air filter / turbocharger and electric sockets


Disconnect electric sockets 1 and 2 and release a cable (fig. 2.80).

Fig. 2.149. Fastening of the giving oil highway of a turbocharger and its support


Turn off the giving oil highway of a turbocharger from the engine 1 (fig. 2.149).
Turn off a bolt 2 support of a turbocharger.
Disconnect the giving oil highway of a turbocharger.

Fig. 2.150. Fastening of the return oil pipeline


Remove the return oil pipeline from a turbocharger (fig. 2.150).

Fig. 2.151. Turbocharger support bolt


Weaken a bolt of 1 support of a turbocharger on 2 turns (fig. 2.151).

Fig. 2.102. Tube of cooling liquid


Disconnect a tube of cooling liquid (fig. 2.102).

Fig. 2.219. Bolts of fastening of a water pipe


Turn off a water pipe 1 (in the presence) from GBTs (fig. 2.219).

NOTE
The nut of a tightening level can be not turned off.

Turn off the top nuts.
Take a turbocharger and a final collector up.

Installation
Installation is carried out in the return sequence.

NOTE
Laying, sealing rings and the self-stopped nuts it is necessary replace.

Fill in in a turbocharger engine oil through a connecting branch pipe for the giving oil pipeline.
Hoses and hose unions of system of pressurization of air have to be cleared before installation of oils and lubricant.
For fastening of all connections of hoses use collars of the corresponding series.
Install final system and to level it freely.
Fill in cooling liquid.
Check oil level.

NOTE
After installation of a turbocharger leave the engine to work at single turns (do not increase turns) within 1 minute that be convinced of supply of oil in a turbocharger.

Inhaling moments
* Replace a bolt or a nut.
** Grease adjusting pins of a final collector or a carving of the lyamda-probe with heat-resistant paste.


2.6. System of injection

2.6.2. Removal and installation of the vacuum block of a turbocharger