servicing charge air system with turbocharger - · pdf fileservicing charge air system with...
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30052008 335 pm5-cyl Diesel Engine Mechanical Components (25 l Engine)
Page 1 of 4http1921680110ElsaWinhtmlRLxmla2804719xml
Servicing charge air system withturbochargerRemoving and installing turbocharger RemovingRemoving
‒ rarr Remove the noise insulation -arrows-
‒ rarr Disconnect hose -5- at
vacuum unit for boost pressurecontrol of turbocharger
‒ Remove the air duct hose -6-from the charge air cooler tothe turbocharger
‒ Place drip container underneathto collect oil
‒ Unscrew the oil return pipe -4-from the turbocharger
30052008 335 pm5-cyl Diesel Engine Mechanical Components (25 l Engine)
Page 2 of 4http1921680110ElsaWinhtmlRLxmla2804719xml
Audi A6Audi A6
‒ rarr Remove engine cover -arrows-
All modelsAll models
‒ Remove air duct to air cleaner atlock carrier
Vehicles with engine codes AATVehicles with engine codes AATAELAEL
‒ rarr Detach connector -5-‒ Detach connector -1- from the
exhaust gas recirculation valve‒ Detach the hoses -2- from the
exhaust gas recirculation valve
All modelsAll models
‒ Remove air intake pipe -3-between charge air cooler andintake manifold
‒ Remove the air duct hose -4- toturbocharger with the hose forcrankcase vent
‒ Remove the upper section of theair cleaner housing
30052008 335 pm5-cyl Diesel Engine Mechanical Components (25 l Engine)
Page 3 of 4http1921680110ElsaWinhtmlRLxmla2804719xml
‒ rarr Detach oil feed pipe -3- atturbocharger
‒ Unbolt front exhaust pipe -1-from turbocharger connection
‒ Unscrew frontturbochargerexhaust manifoldnuts -2-
NotesNotes
For releasing the two rear nuts-2- on theturbochargerexhaust manifoldflange a flat ring spanner 15AF must be bent to fit -arrow-
A flat ring spanner 15 AF issuitable for releasing the nut atthe top front
‒ Remove turbocharger
InstallingInstalling
Installation is carried out in thereverse order note the following
NotesNotes
Always replace seals gasketsand self-locking nuts
Coat threads and bolt headcontact surface forturbocharger with hightemperature lubricant High-temperature lubricant
=gt Parts List
Fill the turbocharger withengine oil via the oil supplyconnection
Secure all hose connections
30052008 335 pm5-cyl Diesel Engine Mechanical Components (25 l Engine)
Page 4 of 4http1921680110ElsaWinhtmlRLxmla2804719xml
with the correct hose clamps(same as original equipment)
=gt Parts List
Charge air system must be freeof leaks
Hose connections and hoses forcharge air system must be freeof oil and grease beforeassembly Lubricants mustnever be used
After installing theturbocharger run engine forapprox 1 minute at idlingspeed do not rev upimmediately This ensures theturbocharger is properlylubricated
‒ Check oil level =gt Page 17-22
Tightening torquesTightening torques
ComponentComponent NmNm
Turbocharger to exhaustmanifold
60
Front exhaust pipe toturbocharger
30
Oil return pipe toturbocharger
30
Oil supply pipe toturbocharger
25
Hose clamps for air ducthoses
35
30052008 335 pm5-cyl Diesel Engine Mechanical Components (25 l Engine)
Page 2 of 4http1921680110ElsaWinhtmlRLxmla2804719xml
Audi A6Audi A6
‒ rarr Remove engine cover -arrows-
All modelsAll models
‒ Remove air duct to air cleaner atlock carrier
Vehicles with engine codes AATVehicles with engine codes AATAELAEL
‒ rarr Detach connector -5-‒ Detach connector -1- from the
exhaust gas recirculation valve‒ Detach the hoses -2- from the
exhaust gas recirculation valve
All modelsAll models
‒ Remove air intake pipe -3-between charge air cooler andintake manifold
‒ Remove the air duct hose -4- toturbocharger with the hose forcrankcase vent
‒ Remove the upper section of theair cleaner housing
30052008 335 pm5-cyl Diesel Engine Mechanical Components (25 l Engine)
Page 3 of 4http1921680110ElsaWinhtmlRLxmla2804719xml
‒ rarr Detach oil feed pipe -3- atturbocharger
‒ Unbolt front exhaust pipe -1-from turbocharger connection
‒ Unscrew frontturbochargerexhaust manifoldnuts -2-
NotesNotes
For releasing the two rear nuts-2- on theturbochargerexhaust manifoldflange a flat ring spanner 15AF must be bent to fit -arrow-
A flat ring spanner 15 AF issuitable for releasing the nut atthe top front
‒ Remove turbocharger
InstallingInstalling
Installation is carried out in thereverse order note the following
NotesNotes
Always replace seals gasketsand self-locking nuts
Coat threads and bolt headcontact surface forturbocharger with hightemperature lubricant High-temperature lubricant
=gt Parts List
Fill the turbocharger withengine oil via the oil supplyconnection
Secure all hose connections
30052008 335 pm5-cyl Diesel Engine Mechanical Components (25 l Engine)
Page 4 of 4http1921680110ElsaWinhtmlRLxmla2804719xml
with the correct hose clamps(same as original equipment)
=gt Parts List
Charge air system must be freeof leaks
Hose connections and hoses forcharge air system must be freeof oil and grease beforeassembly Lubricants mustnever be used
After installing theturbocharger run engine forapprox 1 minute at idlingspeed do not rev upimmediately This ensures theturbocharger is properlylubricated
‒ Check oil level =gt Page 17-22
Tightening torquesTightening torques
ComponentComponent NmNm
Turbocharger to exhaustmanifold
60
Front exhaust pipe toturbocharger
30
Oil return pipe toturbocharger
30
Oil supply pipe toturbocharger
25
Hose clamps for air ducthoses
35
30052008 335 pm5-cyl Diesel Engine Mechanical Components (25 l Engine)
Page 3 of 4http1921680110ElsaWinhtmlRLxmla2804719xml
‒ rarr Detach oil feed pipe -3- atturbocharger
‒ Unbolt front exhaust pipe -1-from turbocharger connection
‒ Unscrew frontturbochargerexhaust manifoldnuts -2-
NotesNotes
For releasing the two rear nuts-2- on theturbochargerexhaust manifoldflange a flat ring spanner 15AF must be bent to fit -arrow-
A flat ring spanner 15 AF issuitable for releasing the nut atthe top front
‒ Remove turbocharger
InstallingInstalling
Installation is carried out in thereverse order note the following
NotesNotes
Always replace seals gasketsand self-locking nuts
Coat threads and bolt headcontact surface forturbocharger with hightemperature lubricant High-temperature lubricant
=gt Parts List
Fill the turbocharger withengine oil via the oil supplyconnection
Secure all hose connections
30052008 335 pm5-cyl Diesel Engine Mechanical Components (25 l Engine)
Page 4 of 4http1921680110ElsaWinhtmlRLxmla2804719xml
with the correct hose clamps(same as original equipment)
=gt Parts List
Charge air system must be freeof leaks
Hose connections and hoses forcharge air system must be freeof oil and grease beforeassembly Lubricants mustnever be used
After installing theturbocharger run engine forapprox 1 minute at idlingspeed do not rev upimmediately This ensures theturbocharger is properlylubricated
‒ Check oil level =gt Page 17-22
Tightening torquesTightening torques
ComponentComponent NmNm
Turbocharger to exhaustmanifold
60
Front exhaust pipe toturbocharger
30
Oil return pipe toturbocharger
30
Oil supply pipe toturbocharger
25
Hose clamps for air ducthoses
35
30052008 335 pm5-cyl Diesel Engine Mechanical Components (25 l Engine)
Page 4 of 4http1921680110ElsaWinhtmlRLxmla2804719xml
with the correct hose clamps(same as original equipment)
=gt Parts List
Charge air system must be freeof leaks
Hose connections and hoses forcharge air system must be freeof oil and grease beforeassembly Lubricants mustnever be used
After installing theturbocharger run engine forapprox 1 minute at idlingspeed do not rev upimmediately This ensures theturbocharger is properlylubricated
‒ Check oil level =gt Page 17-22
Tightening torquesTightening torques
ComponentComponent NmNm
Turbocharger to exhaustmanifold
60
Front exhaust pipe toturbocharger
30
Oil return pipe toturbocharger
30
Oil supply pipe toturbocharger
25
Hose clamps for air ducthoses
35