Removing Turbo from AMF 1.4Tdi

leosun76

Member
Am bravely or stupidly trying to swap my damaged Turbo but got about 20% into the project today and then started to mildly panic. I was not sure that the turbo would come out without removing extra things on the car to make way for it and was wondering if anyone who has done it could give me some advice please? I had another AMF engine delivered last night that has less than half the mileage on than mine. The guy I bought it from has assured me that the engine still has another 50k or so left on it's cam belt and is not necessary to be opened and ready to do a simple swap out with current engine but I am limited on time, funds and experience, so want to use that Turbo in the mean time to give me more time. Hiccup though with the engine that arrived last night is that although it looks great the bolts, nuts etc for the turbo and manifold are pretty rusted so have been soaking it today with WD40 but most remain stuck. Will have a look again tomorrow but have in the mean time put my car back together again - guess is giving me a bit off practice in the mean time. Engine, gearbox, clutch, alternator etc all in tack so is just such a shame I can just swapo the engines out now as probably would be easier and quicker lol
 
A little bit of heat on the turbo nuts will help free them off, a small blow torch may be the best. replace the oil return line gasket as the old one may leak if reused. its also good practice to put some rag in the open hose ports to stop anything falling in them if you drop something, a nut will wreck a turbo in a flash.
 
Am bravely or stupidly trying to swap my damaged Turbo but got about 20% into the project today and then started to mildly panic. I was not sure that the turbo would come out without removing extra things on the car to make way for it and was wondering if anyone who has done it could give me some advice please? I had another AMF engine delivered last night that has less than half the mileage on than mine. The guy I bought it from has assured me that the engine still has another 50k or so left on it's cam belt and is not necessary to be opened and ready to do a simple swap out with current engine but I am limited on time, funds and experience, so want to use that Turbo in the mean time to give me more time. Hiccup though with the engine that arrived last night is that although it looks great the bolts, nuts etc for the turbo and manifold are pretty rusted so have been soaking it today with WD40 but most remain stuck. Will have a look again tomorrow but have in the mean time put my car back together again - guess is giving me a bit off practice in the mean time. Engine, gearbox, clutch, alternator etc all in tack so is just such a shame I can just swapo the engines out now as probably would be easier and quicker lol

When I did it I took the engine out to be honest, as it seemed easier


Sent from my iPhone using Tapatalk
 
When I did it I took the engine out to be honest, as it seemed easier


Thank you. You don’t by any chance have a write up of what was involved in taking out the engine or can point me in the right direction perhaps? Many thanks in advance ??
 
I think I have just found the info on another thread - will try heat the Nuts tomorrow and apparently Inlet manifold needs to come off etc or I must try the drive shaf below but a bit wary trying that one. Got the gaskets for the rest.
 
Hello,

I changed a turbo on mine without taking the engine out. If you are in doubt lay under the car with a torch and work out the disassembly. Make plans of how things come apart using 7Zap and online manuals as a guide. My sketches let me visualise the work I'm about to do. This way there are no surprises. Good luck, you will manage it. Hope these photos are of some use.

IMG_20181229_120047445.jpg

New gaskets all round will be required and new nuts

IMG_20181229_120040033.jpg


It is ridiculously tight in the back of the engine so take absolutely everything out that you know how
IMG_20181229_105452701.jpg


I put the BHC turbo on my AMF by accident. The unit has a better design

IMG_20181229_105517850~2.jpg


The shaft on this turbo was kaput. The fins hit the casing when spun by hand.

IMG_20181229_105919907.jpg


This corner had the worst access. Make sure you have lots of time on your hands when reassembling
 
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Many thanks for the info - I will try again tomorrow after a nights rest. Trouble at mine where I live is there is just no space and my garage is too small can’t swing a cat in there!
 
Many thanks for the info - I will try again tomorrow after a nights rest. Trouble at mine where I live is there is just no space and my garage is too small can’t swing a cat in there!
Also - did you manage to remove the torbo from the top or down the bottom?
 
Morning,

Here are some more pictures of me removing stuff.
IMG_20190210_091752352.jpg


In this picture You will need to remove the engine cover
The metal pipe and the rubber hose that goes into the EGR
I would move the right hand drain cup out of the way so you don't break it

IMG_20190210_091923303.jpg


This is my favourite socket set.
Your car may have those pipe spring clips that are an pain in the butt to remove I would replace them all with jubilee clips when you reassemble.
IMG_20190210_092114489.jpg


On the left hand side of the picture you will need to remove the air intake pipework
I have a catch can on my car seen on the far left

It sounds a bit counter intuitive but the window wiper will need to come off. Get some old towels to protect the windscreen before you start

IMG_20190210_093017889.jpg


Wiper arm removed, this sounds easy but if its not been off in a while it will fight
The scuttle panel needs a slow and steady approach. Work from one side of the car to the other, prise it out of the channel about 1cm all the way along, use a plastic spatula if you don't own trim tools. The scuttle is usually brittle can brake easily.

IMG_20190210_093704930.jpg

Get the expansion tank out of the way



IMG_20190210_093025251.jpg


There are 5 fixing holding the heater intake on. 3 x 10mm nuts and 2 torx screws

IMG_20190210_093906907.jpg


Two 10mm nuts hold this lot on. Unplug the electric connectors and shift the whole lot out of the way.

IMG_20190210_093946696.jpg


Move the intake out to the right and then forwards.

IMG_20190210_094235024.jpg


Get the EGR off using an ball ended allen key and a spanner for extra umph.



Let me know how you are getting on I can try help you through the next stages if you get stuck.

If you remove the lower engine mount front bracket you will be able to get the turbo out the top once you have removed the air intake manifold.
 
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awesome thanks so much - I have confidence - I am nearly down taking the turbo off the other engine and that has taught me a few things so want to get it off and cleaned up and ready and then later this afternoon study and plan for tomorrow and Monday to get mine off the car and fit the other ??????
 
Morning,

Here are some more pictures of me removing stuff.
View attachment 53529

In this picture You will need to remove the engine cover
The metal pipe and the rubber hose that goes into the EGR
I would move the right hand drain cup out of the way so you don't break it

View attachment 53530

This is my favourite socket set.
Your car may have those pipe spring clips that are an pain in the butt to remove I would replace them all with jubilee clips when you reassemble.
View attachment 53531

On the left hand side of the picture you will need to remove the air intake pipework
I have a catch can on my car seen on the far left

It sounds a bit counter intuitive but the window wiper will need to come off. Get some old towels to protect the windscreen before you start

View attachment 53532

Wiper arm removed, this sounds easy but if its not been off in a while it will fight
The scuttle panel needs a slow and steady approach. Work from one side of the car to the other, prise it out of the channel about 1cm all the way along, use a plastic spatula if you don't own trim tools. The scuttle is usually brittle can brake easily.

View attachment 53534
Get the expansion tank out of the way



View attachment 53533

There are 5 fixing holding the heater intake on. 3 x 10mm nuts and 2 torx screws

View attachment 53535

Two 10mm nuts hold this lot on. Unplug the electric connectors and shift the whole lot out of the way.

View attachment 53536

Move the intake out to the right and then forwards.

View attachment 53537

Get the EGR off using an ball ended allen key and a spanner for extra umph.



Let me know how you are getting on I can try help you through the next stages if you get stuck.

If you remove the lower engine mount front bracket you will be able to get the turbo out the top once you have removed the air intake manifold.
 

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Hi is this the pipe spring clips that you mentioned? No idea how to undo this and I need to get this pipe out of the way if I want to slide the turbo out.

I am able and have done most of the above- don’t think I need to remove the water cooler bottle unless really nescessary( looks like mine have less pipes etc than in yours)

The rainy start to the day has delayed me getting under the car but have to get up early in the morning to have a full day. Slightly stressed as not sure where the oil leak is coming from( which I suspect is what starved the Turbo and caused it to go) and guess will only find out once all off - but does not seem the rocker cover gasket is at fault but it is at the rear and near the top it seems. I have all the replacement bolts, gaskets for turbo , inlet exhaust manifold gasket and 2 new oil pipes - just hope there is not another gasket somewhere that I am going to need.
 
Hi is this the pipe spring clips that you mentioned? No idea how to undo this and I need to get this pipe out of the way if I want to slide the turbo out.

I am able and have done most of the above- don’t think I need to remove the water cooler bottle unless really nescessary( looks like mine have less pipes etc than in yours)

The rainy start to the day has delayed me getting under the car but have to get up early in the morning to have a full day. Slightly stressed as not sure where the oil leak is coming from( which I suspect is what starved the Turbo and caused it to go) and guess will only find out once all off - but does not seem the rocker cover gasket is at fault but it is at the rear and near the top it seems. I have all the replacement bolts, gaskets for turbo , inlet exhaust manifold gasket and 2 new oil pipes - just hope there is not another gasket somewhere that I am going to need.
At least got the replacement cleaned and tarted up a bit today.
 

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Many thanks for the info - I will try again tomorrow after a nights rest. Trouble at mine where I live is there is just no space and my garage is too small can’t swing a cat in there!

Could you maybe try a decat installation? That might help with the space requirements.
 
Hi is this the pipe spring clips that you mentioned? No idea how to undo this and I need to get this pipe out of the way if I want to slide the turbo out.

I am able and have done most of the above- don’t think I need to remove the water cooler bottle unless really nescessary( looks like mine have less pipes etc than in yours)

The rainy start to the day has delayed me getting under the car but have to get up early in the morning to have a full day. Slightly stressed as not sure where the oil leak is coming from( which I suspect is what starved the Turbo and caused it to go) and guess will only find out once all off - but does not seem the rocker cover gasket is at fault but it is at the rear and near the top it seems. I have all the replacement bolts, gaskets for turbo , inlet exhaust manifold gasket and 2 new oil pipes - just hope there is not another gasket somewhere that I am going to need.
Screwdriver under the gap of those clamps then get the needle nose pliers to widen it some more and spin it so accessable for the mole grips to clamp it, rock the clamp side to side or tin snip them off try and resist using the hack saw. I've been there and made a right old mess.
Once it's off throw it away and get your jubilee clips at the ready.
Your right about your rocker cover. Looks oil soaked in the corner. Easy fix though once the turbo is done.
 
Screwdriver under the gap of those clamps then get the needle nose pliers to widen it some more and spin it so accessable for the mole grips to clamp it, rock the clamp side to side or tin snip them off try and resist using the hack saw. I've been there and made a right old mess.
Once it's off throw it away and get your jubilee clips at the ready.
Your right about your rocker cover. Looks oil soaked in the corner. Easy fix though once the turbo is done.
Thank you will give it a try tomorrow ??
 
Hello,

Are you OK?,,,.... did you get your turbo fitted?

All the best

Andy
 
Hello,

Are you OK?,,,.... did you get your turbo fitted?

All the best

Andy
Hi there sorry been so busy - It is a sloooooow process for me. I now have nearly off without loosening the engine etc. But I need to order a coolant flange gasket as is leaking there now. Accidentally loosened that bold or should say stupidly. All else fine so far but have given myself time till end of month to get done. It has been a lot of scratching the head moments but having the right kinda tools definitely helps and a neighbour kindly lend me some of his. Will write more tomorrow but short on time at the moment.
 

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Screwdriver under the gap of those clamps then get the needle nose pliers to widen it some more and spin it so accessable for the mole grips to clamp it, rock the clamp side to side or tin snip them off try and resist using the hack saw. I've been there and made a right old mess.
Once it's off throw it away and get your jubilee clips at the ready.
Your right about your rocker cover. Looks oil soaked in the corner. Easy fix though once the turbo is done.
Just get some 1921 pliers. Cheap, much, much safer and much quicker than faffing about with Jubilee clips:


RAB
 
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