tips on removing Sharan 1.9 tdi turbo

[fastbikes76]

Hi guys,

I have diaged my turbo as being totally shot due to the amount of oil pouring into the inter cooler. I bypassed the breather system to make sure its not from there, and sure enough I/C filled up again and loads of over boost cut out issues.

New turbo gets delivered from Essex Turbos tomorrow for £395 plus VAT :approve:

Can anyone give me a very brief rundown on what i need to take of to replace the turbo. I'm a competent technician so just want a 'rough' idea on what does and doesn't need to come off. Its a 2000 face lift with a AUY engine.

Many thanks

:beerchug:

[fastbikes76]

Well i got the turbo today and all i can say is WOW !!!

This is a re-manufactured unit from Essex Turbos including the gaskets/fitting kit for £395 plus VAT delivered. That also includes the return carriage for you old unit when its off.

If i didn't know it was a reman unit, i would have 100% believed it was brand new.

Will post up on Monday how bad a job it is to change :D

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[vwcabriolet1971]

If it's as good inside as it is outside then you've got a bargain.It looks new ! . If it's not new it has new studs fitted . What engine was the turbo for ? It's always nice to see a company prepared to put their nameplate on , shows a bit of pride in their product .

[fastbikes76]

If it's as good inside as it is outside then you've got a bargain.It looks new ! . If it's not new it has new studs fitted . What engine was the turbo for ? It's always nice to see a company prepared to put their nameplate on , shows a bit of pride in their product .


I have worked in the motor trade for about 15 years now and i can 100% say if i didn't know any better that it was a NEW turbo and not reman. They have done an amazing job on it and without opening it can see the compressor and exhaust turbines are new. So its had a brand new core fitted.

Its for my 2000 Sharan 115 Sport. The seals are totally shot in mine and filling the inter cooler with oil. Engine is fine with no oil coming out the breather. I added a catch tank to verify if it was turbo or rings.

My turbo is so bad i get exhaust gasses coming through the intake side of the intercooler pipework :biglaugh:, yet she still boosts pretty strong and returns about 38 mpg. just the turbo shuts down if you flooring it uphill under very hard load..proibably cos the vanes are so clogged up with oilly clag now.

Fitting it on Saturday so hopefully its not a pig of a job.

Cheers

[fastbikes76]

Well i fitted the turbo yesterday and although its time consuming, its not a bad job at all.

[JamesMaidment]

I would appreciate hearing about any tips regarding the replacement of the turbo, eg any snags you found? Did you do it on the floor? What you took off to make it easier, although I have been in the trade at times throughout my life, I feel that at 62 I need all the advice I can get!
The Turbo I got came on its own without the manifold, would you think that might make a difference to the fitting; apart from the obvious I mean as in undoing bolts is it any easier to take out the manifold as well and then assemble the turbo onto the manifold before refitting?
Thank you for your time.
regards
Jim

[rbraddley]

Hi fastbike,

I was reading your post regarding turbo. I was servicing my sharan its a 2003 130 tdi. I removed the plastic undertray and noticed it was saturated with what appears to be oil. On closer inspection there was oil on the black turbo pipe located at the top rear of the engine. When I was driving in france last year fully laydened with trailer camping, the turbo cut off on hill. Nursed her to services and left her cool down for 1 hr. Was fine after that but I had to navigate france not going above 62 mph. My worry is that what you have discribed appears to be my problem. "....... just the turbo shuts down if you flooring it uphill under very hard load..proibably cos the vanes are so clogged up with oilly clag now." Regarding oil leaking all over back of my engine can I fit the leak, or is it the seals of turbo. Sorry my mechanical knowledge is fairly limited, but I dont want the car to leave me down this year again. Going in 3 weeks so I need to diagnose asap.

Your assistance would be much appreciated.

[rbraddley]

Hi fastbike,
I was reading your post regarding turbo. I was servicing my sharan its a 2003 130 tdi. I removed the plastic undertray and noticed it was saturated with what appears to be oil. On closer inspection there was oil on the black turbo pipe located at the top rear of the engine. When I was driving in france last year fully laydened with trailer camping, the turbo cut off on hill. Nursed her to services and left her cool down for 1 hr. Was fine after that but I had to navigate france not going above 62 mph. My worry is that what you have discribed appears to be my problem. "....... just the turbo shuts down if you flooring it uphill under very hard load..proibably cos the vanes are so clogged up with oilly clag now." Regarding oil leaking all over back of my engine can I fit the leak, or is it the seals of turbo. Sorry my mechanical knowledge is fairly limited, but I dont want the car to leave me down this year again. Going in 3 weeks so I need to diagnose asap.
Your assistance would be much appreciated.