Turbo problem P0234. how do I remove the turbo

[Sullydog]

Hi
my sons car BKD 140 engine has been giving error code P0234 Turbo Overboost for a while
reset with a scanner and it is ok for a few days. Or sometimes fails 2-3 times a day

He has asked me to investigate any avenues suggested while he is on holiday (lucky me)

even to the extent of changing the turbo

can anyone guide me through the removal procedure please?

I don't have access to a lift and will be working on the drive from above and below on my back. Is it doable?

any other pointers to check before the decision to swap is taken would be welcomed

thanks

[arman123]

Removing and installing turbocharger Special tools and workshop equipment required

t Spring type clip pliers -VAS 5024 A- Removing Caution If the turbocharger has suffered mechanical damage (e.g. damaged compressor wheel), it is not sufficient merely to fit a new turbocharger. The following work must be performed in order to avoid further damage: t Check air cleaner housing, air filter element and air intake hoses for dirt and foreign particles. t Check the entire charge air system (including the charge air cooler) for foreign matter. t If foreign matter is found in the charge air system, clean all relevant ducts and hoses and renew charge air cooler if necessary. Observe rules for cleanliness when working on turbocharger → Chapter

Engine cover panel (version 1): – Pull dipstick -1- out of guide tube. – Lift engine cover panel at sides -arrows 2- and pull off towards front -arrow 3-. – Re-insert dipstick in guide tube.

Engine cover panel (version 2): – Lift off engine cover panel (outside -1- and inside -2-) by pulling up evenly.

All vehicles (continued): – Pull cover off air duct (release clips on sides) -arrows-.

– Unclip air duct at the bottom by releasing clips -arrows-. – Detach air duct (bottom) together with air hose.

– Unplug electrical connector -1- at air mass meter -G70-. – Detach vent hose -3- and air hose -2-. – Unscrew bolt -4- and remove air cleaner housing.

– Unplug electrical connector -1- at oil pressure switch -F1-. – Remove oil pressure switch -2-. – Detach oil supply pipe at oil filter bracket -3- and at coolant pipe -4-.

– Disconnect hose going to vacuum unit for charge pressure control at separating point -arrow-. Note Shown from rear with engine removed for illustration purposes.

– Remove bolts -1- and -3-. – Move vacuum hoses at rear intake pipe clear to one side. – Disconnect hose -2- for crankcase breather system at air pipe. – Release spring clip -4- with spring clip pliers -VAS 5024 A- and detach air pipe at connection for turbocharger. Note Shown from rear with engine removed for illustration purposes.

– Remove centre noise insulation -fasteners 1 ... 3-.

– Remove noise insulation (right-side) -fasteners 1 ... 3-.

– Remove bolts -1- and -2-. – Remove air pipe (right-side) by lifting retaining clips -arrows- slightly.

– Detach air intake hose from turbocharger by lifting retaining clip -arrow- slightly. – Remove front exhaust pipe → Chapter.

– Remove bolts -1- and -2- and detach support for turbocharger. – Remove oil return pipe -3- at cylinder block.

– Unscrew oil supply pipe at turbocharger and exhaust manifold -arrows-. – Move oil supply pipe to the side.

– Remove connecting pipe for exhaust gas recirculation -arrows-.

– Remove heat shield from exhaust manifold -arrows-.

– Unscrew nuts -arrows-. – Take out exhaust manifold/turbocharger between subframe and body. Installing Installation is carried out in the reverse order; note the following: Note t Renew seals, gaskets and self-locking nuts. t Fill turbocharger with engine oil at connection for oil supply pipe. t Hose connections and hoses for charge air system must be free of oil and grease before assembly. t Secure all hose connections with the correct type of hose clips (same as original equipment)→ Electronic parts catalogue. – Install exhaust system and align it free of stress → Chapter. – Adhere to the instructions for installing air pipes and hoses with plug-in connectors → Chapter. – Install air pipes → Chapter. – Check oil level → Chapter. Note After installing turbocharger, allow engine to idle for approx. 1 minute and do not rev up immediately to ensure turbocharger is supplied with oil. Tightening torques

Component		Nm
Exhaust manifold/turbocharger to cylinder head		25 1)
Heat shield to exhaust manifold/turbocharger		25
EGR connecting pipe to:	Change-over flap	20
Exhaust manifold	25
Oil supply pipe to turbocharger		22
Bracket for oil supply pipe to exhaust manifold		25
Bracket for turbocharger to:	Cylinder block	40
Turbocharger	20
Oil return pipe to cylinder block		30
Oil supply pipe to oil filter bracket		22
Oil pressure switch to oil filter bracket		20
l 1) Renew nuts.

Power unit > 4-cylinder TDI unit injector engine (2.0 ltr. 4-valve), mechanics > Exhaust turbocharger, G-charger > Turbocharger and charge air cooling - vehicles with engine codes AZV, BKD > Removing and installing turbocharger

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found this if it helps

[Sullydog]

Hi and thanks for info
I will print it off today for a reference doc

now im just wondering if my arms are long enough to reach the manifold from underneath LOL

are these manual docs freely available online?

cheers

[arman123]

pm sent

[Sullydog]

Thanks
I will read it when I get to my pc tonight

cheers

[Crasher]

The main thing is you have to take it out to from below which means removing the right hand drive shaft. For a skilled tech with a lift and air tools who has done a few before you are taliking four hours off and five back on IF all the parts are correct. Remember EVERY single nut/bolt removed MUST be replaced... On your back on the drive, evil....