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Removing and installing parts of the charge air cooling for engine with engine identification characters BKD, AZV > < Charge-air system with exhaust gas turbocharger - Part 2

Octavia Mk2

Removing and installing exhaust gas turbocharger for engine with engine identification characters BKD, AZV
   
Removing and installing exhaust gas turbocharger for engine with engine identification characters BKD, AZV
1 - Gasket
q   replace
2 - to flap of radiator for exhaust gas recirculation
3 - 25 Nm
q   replace
q   Coat stud bolts with hot bolt paste -G 052 112 A3-
4 - Connecting tube
q   to flap of radiator for exhaust gas recirculation
5 - Support
q   for oil feed line
6 - 10 Nm
7 - Oil feed line
q   Check oil feed line for continuity before installing.
q   Fill the exhaust turbocharger with engine oil through the connection fitting of the oil feed line before installing
8 - Union nut - 22 Nm
9 - Connection fitting - 30 Nm
10 - Gasket ring
q   replace
11 - Gasket
q   replace
q   Check fitting position
12 - Exhaust gas turbocharger
q   can only be replaced complete with exhaust manifold and vacuum setting element of charge pressure control
q   removing → Anchor
q   installing → Anchor
q   Check vacuum setting element → Chapter
13 - Support
q   between turbocharger and the cylinder block
14 - 40 Nm
q   first tighten all screws by hand
15 - Oil return line
q   in the cylinder block
16 - Connection fittings - 40 Nm
17 - 17 Nm
18 - 20 Nm
q   first tighten all screws by hand
19 - Heat shield
20 - 22 Nm

Special tools and workshop equipment required
t  Pliers for spring strap clamps
  Caution
In case of mechanical damage to the exhaust turbocharger, e.g. damage of the compressor wheel, it is not sufficient to only replace the exhaust 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 foreign bodies are detected in the charge air system, the charge-air routing must be cleaned and the charge air cooler must be replaced.
Removing
–  Remove engine cover → Chapter.
–  Remove the cooling water tank cover → Body Work → Rep. Gr.66.
   
–  Remove bulkhead plenum chamber -arrows-.
–  Remove noise insulation → Body Work → Rep. Gr.50.
–  Remove the right wheelhouse liner bottom part → Body Work → Rep. Gr.66.
–  Remove right drive shaft → Chassis → Rep. Gr.40.
Vehicles with auxiliary heating.
–  Release the screws of the coolant pipes for the auxiliary heating and swivel the coolant pipes to the left.
Continued for all vehicles
  Note
The figure shows the removed engine from a rear view.
  S24-0647
–  Release screws -1- and -3-.
–  Release the vacuum lines at the rear of the charge air pipe and detach hose to vacuum setting element of charge pressure control.
–  Detach hose -2- to crankcase vemtilation from charge air pipe.
–  Release spring strap clip -4- with pliers for spring strap clips and remove charge air pipe from exhaust turbocharger.
  S21-0081
–  Unscrew fixing screws of right charge air pipe and remove connecting hose from exhaust turbocharger; to do so slightly raise the retaining clip -arrow-.
–  Remove pre-exhaust pipe → Chapter.
  S21-0075
–  Release screws -1- and -2- and remove turbocharger support.
–  Remove the oil return line -3- from the cylinder block.
  S21-0076
–  Unscrew oil feed line from exhaust turbocharger and exhaust manifold -arrows- and furthermore from coolant pipe and from oil filter holder and lay it to one side.
  S21-0077
–  Remove connection pipe for exhaust gas recirculation -arrows- and heat shield for exhaust manifold.
  S21-0082
–  Unscrew nuts -arrows- and remove exhaust manifold with exhaust turbocharger downwards.
Install
Installation occurs in reverse order to removal. Pay attention to the following:
  Note
t  Replace the gaskets, the sealing rings and the self-locking nuts.
t  Fill exhaust turbocharger with engine oil through the connection fitting of the oil feed line.
t  Hose connections and hoses for charge air system must be free of oil and grease before being installed.
t  Secure all hose connections with corresponding hose clips.
–  Install pre-exhaust pipe → Chapter.
–  Align exhaust system free of stress → Chapter.
–  Observe the assembly instruction for hose connections with push-fit couplings → Chapter.
–  Checking the oil level → Octavia II.
  Note
after installing the exhaust turbocharger run the engine approx. 1 minute in idle and do not increase speed immediately in order to ensure the supply of oil to the turbocharger.
  S21-0078

Removing and installing parts of the charge air cooling for engine with engine identification characters BKD, AZV > < Charge-air system with exhaust gas turbocharger - Part 2