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-

❑ Removing and installing 

⇒ page 223

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.

– Remove particulate filter 

⇒ page 218

 .

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 

⇒ page 198

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) 

⇒ page 208

 .

⇒ page 218

 .

– 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