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Removing and installing parts of the charge air cooling > < Removing and installing turbocharger - Summary of components|Part 2

Octavia Mk1

Removing and installing turbocharger
Removing and installing turbocharger
Special tools and workshop equipment required
t  Torque wrench
t  Pliers for spring strap clips
t  Hot bolt paste -G 052 112 A3-
  Note
t  Remove the turbocharger to the bottom after removing the exhaust manifold.
t  The vacuum setting element for the charge pressure control valve is a part of the exhaust turbocharger and cannot be replaced separately.
t  Always replace seals and gasket rings.
Removing
–  Remove engine cover.
–  Remove middle and right sound dampening system.
–  Unbolt heat shield for right drive shaft.
–  Remove the right drive shaft from the gearbox → Chassis → Rep. Gr.40.
–  Drain coolant → Chapter.
–  Unbolt coolant feed line at cylinder block.
–  Remove the oil return flow line from the exhaust turbocharger.
   
–  Unplug connector -4-.
–  Separate hose connections -5-, -6-, -7-.
  S15-0186
–  Unscrew the catch for the oil feed line at exhaust turbocharger -1-.
–  Detach the hose -2- to the activated charcoal filter from the connection of the exhaust turbocharger.
  A21-0026
–  Unscrew oil feed line -2- and coolant return-flow line -1- at exhaust turbocharger.
–  Remove distance sleeve below the connection of the coolant return-flow line.
–  Remove coolant return-flow line -1-.
–  Unscrew bracket for exhaust turbocharger from cylinder block and remove exhaust turbocharger to the bottom.
Install
  Note
t  Fill exhaust turbocharger with clean engine oil through the connection fitting of the oil feed line.
t  Replace all bolts and nuts of the exhaust manifold, turbocharger and exhaust pipe and coat thread with hot bolt paste -G 052 112 A3-.
–  Loosely screw on bracket for exhaust turbocharger.
–  Attach exhaust turbocharger on engine from underneath and screw on the bracket by hand at the cylinder block.
  A21-0028
–  Screw on oil feed line -2- (hollow screw, 30 Nm; catch, 10 Nm).
–  Place the distance sleeve on the exhaust turbocharger and connect the coolant return-flow line -1- (hollow screw, 30 Nm).
–  Unscrew exhaust turbocharger bracket from cylinder block.
–  Connect exhaust turbocharger at exhaust manifold.
Further installation occurs in reverse order, while paying attention to the following:
–  Top up coolant → Chapter.
  Note
t  After installing the exhaust turbocharger, run engine at idling speed for about 1 minute to ensure that oil is supplied to the turbocharger bearing.
t  Inspect engine oil level, if necessary top up.
Tightening torques
  A21-0028
ComponentNm
Oil feed line on the exhaust turbocharger30
Oil return line on the exhaust turbocharger10
Bracket for oil feed line to
exhaust turbocharger		10
Coolant feed line at cylinder block35
Coolant return-flow line at
exhaust turbocharger		35
Bracket for turbocharger to turbocharger45
Bracket for turbocharger to cylinder block25
Heat shield on cylinder head25
Socket at top/bottom bracket for top air guide pipe10
Turbocharger to exhaust manifold351)
Front exhaust pipe to
exhaust turbocharger		401)
Heat shield for drive shaft to cylinder block35
Nuts for clamping sleeves of exhaust pipes40

1) Always replace bolts or nuts.
   

Removing and installing parts of the charge air cooling > < Removing and installing turbocharger - Summary of components|Part 2