Audi Q7 Owners & Service Manuals

Audi Q7: Charge Air System

Overview - Charge Air System

Overview - Charge Air System

1 - Seal

  • Replace after removing

2 - O-Ring

  • Replace after removing
  • Coat with engine oil when installing the charge air cooler

3 - O-Ring

  • Replace after removing
  • Coat with engine oil when installing the charge air cooler

4 - Seal

  • Replace after removing

5 - Right Charge Air Cooler

  • Removing and installing. Refer to → Chapter "Charge Air Cooler, Removing and Installing".

6 - Bolt

  • 10 Nm
  • Replace after removing
  • Self-locking

7 - Seal

  • Not available separately.
  • May not be removed from the charge air cooler
  • Coat with engine oil when installing the charge air cooler

8 - Supercharger Housing

9 - Bolt

  • 10 Nm
  • Replace after removing
  • Self-locking

10 - Seal

  • Not available separately.
  • May not be removed from the charge air cooler
  • Coat with engine oil when installing the charge air cooler

11 - Left Charge Air Cooler

  • Removing and installing. Refer to → Chapter "Charge Air Cooler, Removing and Installing".

Overview - Charge Air Hose Connections

  Note

  • The hose connections as well as air duct pipes and hoses must be free of oil and grease before installing.
  • Secure all hose connections with hose clamps that match the ones used in series production. Refer to the Parts Catalog.
  • In order to be able to securely mount the air duct hoses on their connections, spray the bolts on the previously used screw-type clamps with rust remover before installing.

Tightening specification for

A21-10396

1 - Hose clamp -a- = 13 mm wide: 5.5 Nm

2 - Hose clamp -b- = 9 mm wide: 3.4 Nm

Charge Air Cooler, Removing and Installing

Special tools and workshop equipment required

  • Arbor -2033-
  • Seal Installer - Valve Stem Seal Tool -2036-
  • Tire pry lever, commercially available or the Pry Lever -VAG1942-

  Caution

This procedure contains mandatory replaceable parts. Refer to component overview prior to starting procedure.

Mandatory Replacement Parts

  • Bolts - Charged air coolers
  • O-rings - Charged air coolers
  • Seals - Charged air coolers

Removing

  • Supercharger secured on the Engine and Gearbox Bracket -VAS6095A- for repair work. Refer to → Chapter "Supercharger, Securing to Engine/Transmission Holder for Repair Work".

- Remove the bolts -arrows-, and remove the bracket -1- with the bypass valves.

A21-10905

Left Charge Air Cooler:

- Remove the charge air pressure sensor/intake manifold temperature sensor. Refer to → Chapter "Charge Air Pressure Sensor/Intake Manifold Temperature Sensor, Removing and Installing".

Right Charge Air Cooler:

- Remove the Throttle Valve Control Module -J338-. Refer to → Chapter "Throttle Valve Control Module -J338-, Removing and Installing".

- Remove the charge air pressure sensor/intake manifold temperature sensor. Refer to → Chapter "Charge Air Pressure Sensor/Intake Manifold Temperature Sensor, Removing and Installing".

Continuation for Both Sides:

- Remove the bolts -1 and 2- and the coolant pipes from the compressor.

A19-11858

- Remove the charge air cooler bolts on the left -1 and 2- and right -3 and 4-.

A21-10899

- Attach the Seal Installer - Valve Stem Seal Tool -2036- with the Seal Installer - Valve Stem Seal Tool Adapter Plates -2036/1- to the supercharger as illustrated.

- Position the Arbor -2033- on the front of the charge air cooler.

- Slowly remove the charge air cooler with even pressure from the supercharger housing using the Tire Pry Lever -VAG1942-.

A21-10802

Installing

  Note

  • Replace the seals, O-rings and self-locking screws after removing.
  • Always clean the threaded holes inside the supercharger housing with a thread tap before assembling.

- Check the seal -5- on the charge air cooler -4-.

  • The seal must not be cracked or damaged.

- Slide the seal -1- onto the charge air cooler.

- Insert the O-ring -2- into the opening in the supercharger housing -3-.

A21-10803

- Coat the sealing surface -arrow A- and the charge air cooler seal -arrow B--1- with engine oil.

- Coat the inner sealing surface inside the supercharger housing with engine oil.

A21-10455

- Make sure the seals are opposite the openings in the supercharger housing when installing the charge air cooler -arrows-.

A21-10504

  Note

Holding the supercharger housing perpendicular in the Engine and Gearbox Bracket -VAS6095A- makes it easier to install and remove the charge air cooler.

  Caution

Danger of causing damage to the charge air cooler.

Install the charge air cooler by hand only.

- Install the charge air cooler all the way into the supercharger housing by hand in direction of -arrow A-. When doing this, let the front of the charge air cooler slide into the hole -arrow B- inside the supercharger housing.

A21-10900

- Manually guide the charge air cooler by hand through the supercharger housing openings -arrows-, if necessary.

- As soon as it is possible, install the two bolts loosely by hand to help guide the charge air cooler.

  Caution

Danger of causing damage to the charge air cooler.

  • The charge air cooler may not be installed by using the bolts.
  • Install the charge air cooler by hand only until there is maximum 1 mm between the sealing flange and the seal and the supercharger housing. Only then should the bolts be tightened as follows:

A21-10901

- Tighten the bolts for the left -1 and 2- and right -3 and 4- charge air coolers in a diagonal sequence and in small steps.

Installation is performed in reverse order of removal, while noting the following:

- Install the coolant pipes to the supercharger. Refer to → Chapter "Supercharger Coolant Pipes, Removing and Installing".

- Install the Throttle Valve Control Module -J338-. Refer to → Chapter "Throttle Valve Control Module -J338-, Removing and Installing".

- Install the charge air pressure sensor/intake manifold temperature sensor. Refer to → Chapter "Charge Air Pressure Sensor/Intake Manifold Temperature Sensor, Removing and Installing".

- Check the supercharger for leaks. Refer to → Chapter "Supercharger, Checking for Leaks".

A21-10899

Tightening Specifications

  • Refer to → Chapter "Overview - Charge Air System"

Charge Air Pressure Sensor/Intake Manifold Temperature Sensor, Removing and Installing

  Caution

This procedure contains mandatory replaceable parts. Refer to component overview prior to starting procedure.

Mandatory Replacement Parts

  • O-ring - Charge Air Pressure Sensor/Intake Manifold Temperature Sensor

Removing

- Remove the supercharger. Refer to → Chapter "Supercharger, Removing and Installing".

- Remove the bolt -2- and remove the charge air pressure sensor/intake manifold temperature sensor -1-.

A21-10906

Installing

Install in reverse order of removal and note the following:

  Note

  • Replace the self-locking screws and O-ring after removal.
  • Clean the threaded holes for the charge air pressure sensor inside the supercharger housing with a thread tap before assembling.

- Install the supercharger. Refer to → Chapter "Supercharger, Removing and Installing".

Tightening Specifications

  • Refer to → Chapter "Overview - Supercharger"

Special Tools

Special tools and workshop equipment required

  • Used Oil Collection and Extraction Unit -SMN372500-

W00-11526

  • Counterhold - Multiple Use -T10172A- with Counterhold - Kit - Adapter 5 -T10172/5-

W00-11244

  • Gearbox Support -T40206- with -T40206/1-

W00-10759

  • Plate -T40285-

W00-11106

  • Clutch Module Puller -T40301-

W00-11499

  • Clutch Module Centering Device -T40302-

W00-11561

  • Thrust Piece -T40303-

W00-11586

  • Supercharger Module Support -T40304-

W00-11488

  • Turbo System Tester Kit Adapter - VAG1687/4-, T urbo System Tester Kit - Adapter 10 -VAG1687/10-, Turbo System Tester Kit - Adapter 13-1 -VAG1687/13-1- and Turbo System Tester Kit - Adapter 13-2 -VAG1687/13-2-

W00-11217

  • Engine and Gearbox Bracket -VAS6095A-

W00-11310

  • Engine Bung Set -VAS6122-

W00-11228

  • Container of the Coolant Collection System -VAS5014- or the Shop Crane - Drip Tray -VAS6208-

W00-11209

  • Hose Clip Pliers -VAS6362-

W00-11227

  • Bearing/Bushing Installer - Multiple Use -VW295-

W00-11417

  • Arbor -2033-

W00-0774

  • Seal Installer - Valve Stem Seal Tool -2036-

W00-10141

  • Hose Clamps - Up To 25mm -3094-

W00-11130

  • Bearing Installer - Wheel Bearing -3144-
  • Turbo System Tester Kit -VAG1687-
  • Test Adapter For Compressor Module -VAS6909A-
  • Internal Puller -VAS501001-
  • Tire pry lever, commercially available or the -VAG1942-

W00-11368

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