What is the cracked turbo hose Fix ?
A. The cracked turbo hose fix, our ADAP06 is a billet aluminum adaptor that replaces the metal end on the intake side turbo hose found on the driver’s side on the 2.7 liter, 5 cyl. In-line Mercedes Benz turbo diesel engine found in 2002 up to2007 Dodge Sprinter Vans. Our Hose adapter has a nicely rounded end which resists hose cracking even in high temperatures, high vibration and high boost pressures. The Sprinter chassis is becoming increasingly popular with RVers and commercial users because of its great fuel economy and driver-friendly characteristics. However, the intake turbo hose with its flawed metal ends is causing the Sprinter chassis to suffer an inordinate amount of breakdowns.
Removal, overhaul and installation procedures are covered in this article. If component removal and installation is primarily an unbolt and bolt-on procedure, only a torque specification may be furnished.
Removal & Installation
1) Fuel pump assembly is located inside fuel tank. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Raise vehicle on hoist. Drain fuel into suitable container. Disconnect electrical connectors and fuel hoses at fuel tank.
2) Remove fuel filler hose from fuel tank. Remove nuts securing fuel tank. Remove fuel tank from vehicle, and remove fuel pump assembly. To install, reverse removal procedure. Tighten nuts to specification. See TORQUE SPECIFICATIONS table at end of article.
Step 1- Remove motor cover
This is the small triangular cover in the front of the engine where the dipstick is located (figure 1). Just twist the two screws 90 degrees counterclockwise. Then lift up the cover. The cover fits onto a rubber round mount at the point on the “triangle” as well. It’s just pressed on there.
Removal of stock valves:
Removal of the stock diverter valves requires removal of decorative engine cover with the “V6 BITURBO” badging. Lift off the cover after twisting X-shaped plastic fasteners 90 degrees with a flat blade screw driver. Valve replacement is much easier done on a cool engine.
With the DV1 Diverter Valve, we believe you have purchased the finest diverter valve for the money. Follow these instructions, and you’ll have your new A.W.E. Tuning DV1 Diverter Valve installed quickly and easily.
Step 1: Here’s an overview picture of the transverse 1.8T engine found in the Audi TT, VW Golf/Jetta/New Beetle 1.8T. The 225hp TT engine looks a little different, but the install of the A.W.E. Tuning valve is the same procedure. For picture clarity, and ease of install, the decorative engine cover has been removed. Removing the cover is easily done by twisting the “+” shaped fasteners on the cover 90 degrees. They’ll pop up when free, allowing you to grab the cover and lift it up and out of the engine bay. (New Beetle requires removing 2 10mm nuts hidden under trim caps, and then sliding forward and out) We’ve also removed the PCV damper in the following pictures for clarity. You won’t need to remove this item to install the valve.
Congratulations on your purchase of the AWE/McNeil Competition Intercoolers for your 2.7T Audi. Hundreds of hours of design and operational testing were spent to ensure maximum results without compromise. You have truly selected the best performing intercooler kit for the 2.7T engine. While the install is fairly straight forward, please review these instructions carefully before attempting installation. If you do not feel comfortable installing this kit on your own, contact a professional installer in your area. While the car pictured is an Audi S4, installation except where noted is similar on both the A6 and allroad 2.7T.
We appreciate your purchase of the new Stratmosphere HyperFlow high performance induction kit for your supercharged Audi S4. Your smart choice is a great reflection of your intelligence and discerning taste! You now own the first truly custom induction system for the supercharged S4 in the world. One that has a custom fit and makes real power. Make sure you carefully read our instructions prior to installation and get your tools ready for an easy job. As always, we are here to help and we want to make sure you enjoy your S4 to the maximum!
Step 1: Complete kit. Make sure you have all the components before you begin your installation
Step 2: Complete stock intake
Step 3: a. Remove two screws holding factory fresh air duct in place.
b. Pull fresh air duct out of vehicle and save for later use
Step 4: a. . Remove two screws holding top half of airbox in place.
b. Loosen clamp holding factory tube in place.
c. Unplug MAF Sensor.
Step 5: Remove top half of factory airbox.
Step 6: Remove clamp holding top breather filter on factory tube.
Step 7: Remove clamps holding second breather from top of factory tube. Save elbow for later use.
Step 8: Remove clamps holding third breather filter from top of factory tube. Plug can be disconnected for ease of removal.
Step 9: Loosen clamp holding fourth breather down from top of tube with slotted screwdriver.
Step 10: Loosen clamp at turbo and Last breather tube. Pull factory tube out of vehicle.
Step 11: Pull off front grill near Passenger side fog lamp
Step 12: Remove fog light from vehicle.
Step 13: Disconnect Air pump hose at pump.
Step 14: Remove fitting from air pump hose and install provided breather filter. Install filter onto air pump and replace fog lamp and grill.
Step 15: Remove MAF Sensor from top half of air box.
Removing And Installing Instrument Panel
1 Remove instrument panel bottom section (1()
2 Remove A-pillar trim on left and right
3 Remove upper section of air outlet panel (1) Long wedge: See Special Tools below.
4 Unscrew screws (3) from upper side of instrument panel
5 Remove instrument cluster (A1 remove
6.1 Disconnect sun sensor connector
NOTE: Only as of 01.09.01: Connector is located behind instrument cluster
1. Vehicle Disassembly. (a) Place the Vehicle in Park and have the Parking Brake Set before disconnecting the Battery. (b) Remove the Negative Battery Cable (Fig. 1-1) (1) Protect the Fender before starting. (2) Note the Battery Cable position, as it will be re- installed in the same position. CAUTION: Do not touch the positive terminal. (c) Remove the Glove Box Under Cover. (Fig. 1-3) (1) Begin by protecting the Vehicle Interior with Blankets. (d) Remove the Passenger’s Step Cover. (Fig. 1-4) (e) Remove the Passenger’s Cowl Cover. (Fig. 1-5) (1) Remove 1 Nut. (f) Remove 2 Bolts from the Glove Box, then open the Glove Box Door. (Fig. 1-6) (g) Remove 3 Screws from the Glove Box. (Fig. 1-7) CAUTION: Sharp Metal Edges. (h) Dislodge the Glove Box. (Fig. 1-7) (i) Disconnect all Connectors from the Glove Box. (Fig. 1-8) (j) Remove the Cable Clamp from the Glove Box. (Fig. 1-8)