Audi A8 2003 Workshop Manual page 263

8-cylinder TDI engine (4.2 ltr. 4-valve common rail), mechanics - Edition 12.2013
– Unscrew exhaust gas temperature sender 1 for bank 2 - G236-
-item 1- from turbocharger.
– Unscrew bolts -arrows- at top of turbocharger.
– Take out turbocharger downwards.
Installing
Installation is carried out in the reverse order; note the following:
Note
Renew gaskets, seals, O-rings and self-locking nuts.
♦
Hose connections and hoses for charge air system must be
♦
free of oil and grease before assembly.
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Secure all hose connections with the correct type of hose clips
with respect to the correctness of information in this document. Copyright by AUDI AG.
(same as original equipment) ⇒ Electronic parts catalogue .
Charge air system must be free of leaks.
♦
Fit all cable ties in the original positions when installing.
♦
Fill turbocharger with engine oil at connection for oil supply
♦
line.
After installing turbocharger, allow engine to idle for approx. 1
♦
minute and do not rev up immediately to ensure turbocharger
is supplied with oil.
– Bolt turbocharger to exhaust manifold.
– Fit support for turbocharger free of stress:
1. Screw in all bolts finger-tight.
2. Pre-tighten bolt securing support to turbocharger to an initial
torque of 10 Nm.
3. Pre-tighten bolt securing support to sump (top section) to an
initial torque of 10 Nm.
4. Tighten bolt securing support to turbocharger to final torque
(40 Nm).
5. Tighten bolts securing support to sump (top section) to final
torque (22 Nm).
– Install exhaust gas temperature sender 1 for bank 2 - G236-
⇒ page 281 .
– Install coolant pipe (left-side)
– Install starter catalytic converter (left-side)
– Install subframe ⇒ Rep. gr. 40 .
– Tighten subframe bolts only to specified torque (do not turn
further). Do not tighten bolts to final setting until after wheel
alignment check has been performed ⇒ Rep. gr. 40 .
WARNING
The vehicle must not be driven at this stage.
– Install anti-roll bar ⇒ Rep. gr. 40 .
– Install radiator cowl
– Install radiator ⇒ page 242
⇒ page 232 .
⇒ page 295
⇒ page 246 .
.
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1. Servicing charge air system with turbocharger
Audi A8 2003 ➤
257