This took 8 hours with 2 people the first time. We both think about 6 hours or less the next time. We didn’t know the water pump pulley, vacuum pump and air box removal was required. The supercharger part is easy the stuff in the tight quarters up in front not so much. In the end I saved $1250 plus would feel comfortable doing this on friends vehicles.
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SUPERCHARGER REMOVAL
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1- Engine lifting eye
2- Bolt
27Nm
3- Supercharger
With charge air coolers
Removing and installing supercharger.
Charge air coolers - exploded view.
4- Insulating plate
5- Bolt
5Nm
6- Rubber grommet
2x
7- Intermediate flange
8- Bolt
Tightening torque*>*Rep. gr.24
9- Throttle valve module -J338-
Removing and installing > Rep. gr.24
10- O-rings
Renew
11- Connection
12- Bolt
Tightening torque and sequence > Rep. gr.24
13- Bracket For change-over valves
14- Bolt
9Nm
15- Bolt Tightening torque and sequence > Rep. gr.24
16- Intermediate flange
17- Regulating flap control unit -J808-
Removing and installing > Rep. gr.24
18- Bleeder screw For charge air cooler (left-side)
1.5 … 3.0 Nm
19- Bolt
Tightening torque > Rep. gr.24
20- Intake air temperature sender -G42-
Removing and installing > Rep. gr.24
21- O-rings
Renew
22- Nut
20Nm
23- O-ring
Renew
24- Threaded pin
17Nm
25- Bolt Self-locking
Renew
Before assembly, always remove residues from threaded holes using a thread tap
10Nm
26- Charge pressure sender
Cylinder bank 1 (right-side): charge pressure sender -G31-
Cylinder bank 2 (left-side): charge pressure sender*2 -G447-
Removing and installing.
27-Seals
Renew
28- O-ring
Renew
29- Connection For crankcase breather
Installation position*>*Fig.
30- O-ring
Renew
Removing:
Remove poly V-belt for supercharger.
Remove both belts:
Supercharger easiest from underneath. 16mm
Accessory belt from the top. 17mm
Place drip tray for workshop hoist -VAS 6208- beneath engine.
Tip* Extract the coolant from the reservoir, squish the radiator hose and this will force more coolant in to reservoir. No coolant will be come out of the supercharger hoses this way.
Clamp off coolant hoses using hose clamps -3094-, release hose clips -1- and detach coolant hoses from coolant pipes on supercharger.
http://i689.photobucket.com/albums/vv257/BRD-PREY/1_coolant%20pipes_zpsawmljmnj.jpg
Tip* Take a silver and black sharpie and mark ALL vacuum hoses and connectors before removing.
Move fuel hose -1- and hose -2- from activated*charcoal filter clear at air pipe.
Detach vacuum hose -3- from connection on air pipe.
Remove air pipe. To do so, release hose clip -4- and clamps -arrows-.
Remove air box, optional but it makes for a lot more visibility.
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Unplug electrical connector -3- at activated charcoal filter solenoid valve 1 -N80- and detach vacuum hose -4- (press release tabs).
Detach activated charcoal filter solenoid valve 1 -N80- from bracket and move it clear to the side with hose still attached.
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Unplug electrical connector arrow at throttle valve module -J338-.
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Unplug electrical connector arrow at regulating flap control unit -J808-.
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Unplug electrical connectors 1, 2, 3.
Note: Mark position of vacuum hoses for re-installation.
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Disconnect vacuum hoses 4…7.
Unplug electrical connector 1 at intake air temperature sender -G42-/intake manifold pressure sender -G71-.
Note: Disregard arrows.
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If fitted, unplug electrical connector 3 and disconnect vacuum hoses 1 and 2.
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Move clear vacuum hose 1.
Remove bolts -arrows-on both sides and detach cover/bracket
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Move clear vacuum hose 2 leading to brake servo at bracket 1.
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Unplug electrical connectors -1- and -2-.
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Remove nuts -arrows- and lift off supercharger with charge air coolers.
Tip* Place long 3/8 extensions thru the engine lifting rings to provide a good hand hold.
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Seal openings on supercharger and all relevant ducts and hoses of the charge air system with plugs from engine bung set -VAS 6122-.
Detach noise insulation panels.
Installing
Installation is carried out in the reverse order; note the following:
Tightening torques. „Supercharger - exploded view“
Renew seals and/or gaskets.
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 secure the air hoses at their connections, spray rust remover onto the worm thread of the used hose clips before installing.
Ensure that crankcase breather connection is positioned correctly > Fig. when fitting supercharger.
Install poly V-belt for supercharger
Fill up with coolant
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1-Bolt
9nm
2-Coolant*pipes (front left).
Removing and installing.
3-Bolt
9Nm
4-Bolt
9nm
5-Bracket
6-Bolt
22Nm
7-Retainingclip
8-Bolt
9Nm
9-Coolant*pipe (front)
Removing and installing.
10-Seal
Renew
11-O-rings
Renew
12-Coolant*temperature sender -G62-
Removing and installing.
13-Coolant pipe (bottom) on supercharger
Remove and install together with-item 17-.
14-Bolt
5Nm
15-Dowel sleeve
2x
16-Bolt
5Nm
17-Seals
Renew
18-Coolant pipe (top) on supercharger
Remove and install together with -item 11.
19-O-ring
Renew
20-Coolant*pipe (top)
Removing and installing .
21-Bolt
9*Nm
22-Seal
Renew
23-Bolt.
9Nm
24- Bolts.
9Nm
25- Coolant*pipes (left-side)
Removing and installing.
26- O-ring
Renew
Coolant Pipes Remove and Replace
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Removing and installing coolant pipe (front)
Special tools and workshop equipment required Pin Wrench 3212
Tip* You must remove the water pump pulley to remove the front coolant hose out of the thermostat. I bought a Pin Wrench off Amazon for Audi and VW. $14
Removing
Draincoolant.(or on vehicles equipped withcontinuedcoolantcirculationpump -V51- removecontinuedcoolantcirculationpump.).
Remove air duct -arrow-.
Remove coolant pipes (front left)
Remove poly V-belt:
Remove vacuum pump>Rep. gr.47.
*Tip 3 bolts you can then flip it up out of the way.
Remove bolts for Coolant pump pulley (counterhold with pin wrench -3212-).
Detach poly-V-belt pulley.
http://i689.photobucket.com/albums/vv257/BRD-PREY/27_Pin%20Wrench_zpsos5ievnz.jpg
Since we are not removing the coolant pipe all the way this is where we remove the 5 bolts holding the coolant pipe into the thermostat housing.
Unplug electrical connector -3- at coolant temperature sender -G62-.
Lift retaining clips and disconnect coolant hoses -1 and 4-.
Release hose clip-2-and detach coolant hose (top).
Loosen hose clip-5-.
Unscrew bolts-arrows-and removecoolantpipe*(front)
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http://i689.photobucket.com/albums/vv257/BRD-PREY/Vacuum%20pump%20flipped%20up_zps0ucn7blp.jpg
Installation is carried out in the reverse order; note the following:
Tightening torques. „Coolant pipes - exploded view“
Note
Renew seals and O-rings.
Secure all hose connections with the correct type of hose clips (same as original e.~uipment)>*Electronic parts catalogue.
Clean or smoothen sealing surfaces for seals and O-rings.
Lubricate seals and O-rings with coolant and slide onto coolant pipe.
Connect coolant hose with plug-in connector>Fig…
Install coolant pipes (left-side)…
Install air conditioner compressor>Rep. gr.87.
Install poly V-belt pulley for coolant pump…
Install vacuum pump>Rep. gr.47.
Install poly V-belt:
„Removing and installing poly V-belt - vehicles with hydraulic power steering“.
„Removing and installing poly V-belt - vehicles with electromechanical power steering“.
Install coolant pipes (front left)…
Install continued coolant circulation pump -V51-…
Fill up with coolant:
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http://i689.photobucket.com/albums/vv257/BRD-PREY/Top%20thermostat_zps1uwsojlo.jpg
1-Bolt
9Nm
2-Bolt
20Nm
3-Poly V-belt pulley for coolant pump
4-Coolant pump
With seal
Removing and installing.
5-Bolt
9Nm
6-Bolt
Tightening torque>Item
7-Washer
8-Idler roller for poly V-belt
9-Connection
For coolant hose
10-Gasket
Renew
11-Gasket
Renew
12-Thermostat
13-Bolt
9*Nm
14 -Coolant valve for cylinder head -N489-
Thermostat Remove and Replace
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http://i689.photobucket.com/albums/vv257/BRD-PREY/Engine%20Thermo%20removed_zpsspl6h09p.jpg
Checking Thermostat
Heat removed thermostat in water bath.
Starts to open
Fully open
Opening travel
approx. 87 °C
approx. 102 °C*1)
at least 8 mm
1)Cannot be tested.
COOLANT FILL and BLEED
Place a cloth underneath to catch escaping coolant.
Tip* A mechanical impact driver with a #3 phillips is best for loosing the bleed screws.
2000 rpm is required for coolant to be forced into the supercharger and heater core.
Open bleeder screws -1-and-2- one after the other until coolant flows out.
Close bleeder screws.
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http://i689.photobucket.com/albums/vv257/BRD-PREY/Hammer%20impact%20screwdriver_zpsaisazjgv.jpg
Pull seal off plenum chamber partition panel.
Remove plenum chamber cover >Rep. gr.50.
http://i689.photobucket.com/albums/vv257/BRD-PREY/21_plenum%20access_zpsycgzij6t.jpg
Release coolant hose going to heat exchanger and pull back hose until coolant flows out at bleeder hole -arrow- in coolant hose.
Push coolant hose back onto connection andsecurewith spring-type hose clip.
Onvehicleswith auxiliary heater, switch heater on (for about 30 seconds) and then off again.
Tighten filler cap on expansion tank, making sure it engages.
Start engine.
Set temperature to „HI“ for all zones and select lowest blower speed (= 0).
Switch off air conditioner compressor (press AC button).
LED in button should not light up.
Run engine for 3 minutes at 2000*rpm.
Allow engine to run at idling speed until two large coolant hoses at radiator become warm.
Run engine for 2 minutes at 2000rpm.
Switch off ignition and allow engine to cool down.
Install noise insulation > Rep. gr.66.
http://i689.photobucket.com/albums/vv257/BRD-PREY/22_heater%20core%20bleed_zpse8npsmok.jpg
Check coolant level.
The coolant level must be at the MAX marking when the engine is cold.
The coolant level can be above the MAX marking when the engine is warm
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