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Checking the charge-air system for leaktightness > < Removing and installing charge air cooler

Fabia Mk1

Removing and installing exhaust gas turbocharger
Removing and installing exhaust gas turbocharger
Special tools and workshop equipment required
t  Pliers for spring strap clamps
  Caution
In case of mechanical damage to the exhaust gas turbocharger, e.g. damage of the compressor wheel, it is not sufficient to only replace the exhaust gas turbocharger. In order to prevent consequential damage to the engine, perform the following tasks:
t  Clean all oil lines.
t  Change engine oil and oil filter.
t  Check air filter housing, air filter element and charge air pipes as well as charge air hoses for soiling.
t  Check all the air guides and the charge air cooler for foreign bodies.
If soiling or foreign bodies are detected in the filling system, all air guides must be carefully cleaned and if necessary replace the charge air cooler.
Removing
–  Remove engine cover → Chapter.
   
–  Remove charge-air pipe at the top -1- with connecting hose -2--arrows-.
–  Remove connecting hose from rear charge air pipe and air filter → Chapter.
–  Removing rear charge air pipe (Pos. 14) with connecting hose to turbocharger → Chapter.
–  Remove the air guide from the lock carrier and the air filter → Chapter.
–  Unscrew the oil feed line from the exhaust turbocharger → Chapter (Pos. 30), → Chapter (Pos. 21).
–  Removing connecting tube inlet connection/exhaust manifold → Chapter.
–  Remove intake manifold with mechanical exhaust gas recirculation valve:
t  For engine with identification characters AMF → Chapter (Pos. 3).
t  For engine with identification characters BNM, BNV → Chapter (Pos. 2).
–  Unscrew pre-exhaust pipe:
t  For engine with identification characters AMF → Chapter (Pos. 26).
t  For engine with identification characters BNM, BNV → Chapter (Pos. 18).
–  Remove the noise insulation.
–  Unscrew the propeller-shaft guard from the cylinder block.
–  Removing bottom charge air pipe (Pos. 19) with connecting hose to turbocharger → Chapter.
–  Pull out vacuum hoses from the exhaust turbocharger → Chapter.
–  Unscrew oil return line from exhaust turbocharger:
t  For engine with identification characters AMF → Chapter (Pos. 23).
t  For engine with identification characters BNM, BNV → Chapter (Pos. 15).
–  Remove cover plate:
t  For engine with identification characters AMF → Chapter (Pos. 10).
t  For engine with identification characters BNM, BNV → Chapter (Pos. 11).
–  Remove exhaust manifold and take out with turbocharger upwards:
t  For engine with identification characters AMF → Chapter (Pos. 1).
t  For engine with identification characters BNM, BNV → Chapter (Pos. 1).
For engine with identification characters AMF
–  Remove turbocharger → Chapter (Pos. 28) from exhaust manifold.
Install
Installation occurs in reverse order. Pay attention to the following:
  Note
t  Tightening torques: for engine with identification characters AMF → Chapter, for engine with identification characters BNM, BNV → Chapter.
t  Always replace self-locking nuts with new ones.
t  Fill exhaust turbocharger with engine oil through the connection fitting of the oil feed line.
t  After installing the exhaust turbocharger, run engine at idling speed for about 1 minute to ensure that oil is supplied to the exhaust turbocharger.
–  Checking the oil level → BookletFabia.
  S10-0371

Checking the charge-air system for leaktightness > < Removing and installing charge air cooler