229,000Miles turbo failure 1.9tdi/timing Belt

[slackda]

Hi guys, Hope you can help on a couple of questions.

Think i had turbo failure yesterday, (crap load o white smoke and no power).

In the process of removing the Turbo, but not sure
1. where to get a reman turbo from and
2. whether to just remove the turbo or the complete unit i.e include the exhaust manifold etc.

Whilst disconnecting the Air flow housing and associated pipes, i noticed that sitting in the bottom of the bay the pulley pictured below......no i have no idea what or where this is from, i am assuming it is something to do with the AC compressor as the AC has never worked since i got the car , approx 2 years ago, and as its never that hot in the UK never really thought about it.

18841

Also whilst im at it im going to take the front end off and do a Timing Belt change ( i can't find any evidence in the service history that this has ever been done.....), is it worth while doing the water pump whilst i'm at it of just leave it if i'm not having any troubles?
Another question on this topic of the timing belt is there any where in the UK that sells the Tools/Rents them as google keeps giving me USA crap, or should i do a Russian roulette change and mark it all with nail varnish....

Thank you very much Slack

[spartacus 68]

Thermostat and water pump should be done as a matter of course, along with auxilliary belts. Use G12 coolant, etc. Regards tools - worth investing in the right gear. You can always flog it afterwards. Could be there is an a forum member near by that would be prepared to loan you them. :approve:

[audia4qts]

Not sure on the audi but think the manifold and turbo might be in one. they are like that on the newer golfs.
i had a turbo for a 1.9 golf done with a company on ebay they had quick turn around and they seamed to do a good job.

[Mudchute]

I'm just about to change my turbo and after much head scratching I think the easiet way might be to undo the manifold form the head and then disconnect the exhaust pipe along the straight section about midway under the car then feed the lot out through the engine bay. Sounds a work up but getting to the cat bolts on the turbo and where the cat bolts to the exhaust is a nightmare!!! Having that whole lot out will make it easier to take apart especially if there's any seized bolts.

Re the belt, I used an 18mm spanner shank to locate the rear of the camshaft and a 3/8 drive 10mm deep socket (which tapers down on the outside) which fits perfectly into the pump pulley hole. You'll VCDS or VCDS Lite to do the pump timing though. All that combined resulted in an engine that now pulls very strongly.

[slackda]

Not sure on the audi but think the manifold and turbo might be in one. they are like that on the newer golfs.
i had a turbo for a 1.9 golf done with a company on ebay they had quick turn around and they seamed to do a good job.

Looks like they are seperate units but due to bolt placement on further inspection easier to get the whole unit off.
Ty

[audia4qts]

normally easier that way. never done a diesel audi before only golfs but should be quite straight forward though.

[adamss24]

Get a pd 130 turbo whilst you're at it, from the pictures it looks like you have a PD 115 tdi engine, either AJM ot ATJ, they have the same turbo like the old AFN engine wich is a GT1749V. The pd 130 turbo is a later generation GT1749VA, it will spool quicker and hold more boost- ideal if you plan a power upgrade like a remap !

[slackda]

Get a pd 130 turbo whilst you're at it, from the pictures it looks like you have a PD 115 tdi engine, either AJM ot ATJ, they have the same turbo like the old AFN engine wich is a GT1749V. The pd 130 turbo is a later generation GT1749VA, it will spool quicker and hold more boost- ideal if you plan a power upgrade like a remap !

Not sure of the Exact Engine, its the 2000-2001 facelift Model with the Higher BHP 1.9Tdi, From Wikipedia:

1.9 TDI I4 8v SOHC PD (http://en.wikipedia.org/wiki/List_of_Volkswagen_Group_diesel_engines#1.9_R4_TDI _PD_43-118kW)
115 PS (85 kW; 113 bhp)
285 N·m (210 lbf·ft)
185 km/h (115.0 mph)
10.5 sec
2000–2001
123 g/km




so i could pop one of these in:

http://www.ebay.co.uk/itm/Reconditioned-Garrett-GT1749VA-Turbocharger-For-1-9-TDi-ASZ-130-038-253-016-F-/130794632377?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item1e73f7b4b9

How long would i have before i would have to remap ? money is a big factor in this.

[adamss24]

That's the wrong turbo for your car, the turbo in the listing is for a tranverse engine so it has integral manifold. You could use the CHRA (central rotating assembly) and swap it to your turbo. This is what you need, the outlet will need modifying as it's different to the one you have. You can either get the right adapter or use a pd 130 boost hose, plenty info on the internet !
turbo 717858-5009s oj01615w gt1749va garrett afv awx bpw passat audi a4 superb | eBay (http://www.ebay.co.uk/itm/turbo-717858-5009s-oj01615w-gt1749va-garrett-afv-awx-bpw-passat-audi-a4-superb-/261143566892?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item3ccd5e9a2c)

That's the adapter you need on the right-easy to remove from the hose, however this is too expensive you need to look for a cheaper one:
VW GOLF MK5 JETTA TOURAN 1.9 TDI TURBO HOSE BOOST PIPE 1T0 145 790 | eBay (http://www.ebay.co.uk/itm/VW-GOLF-MK5-JETTA-TOURAN-1-9-TDI-TURBO-HOSE-BOOST-PIPE-1T0-145-790-/170802302646?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item27c49c4eb6)

[slackda]

Ty Adamss,
So i could get one of these

Audi 1.9D Brand New Turbocharger - 717858-0009 / 717858-5009S / GT1749V Turbo | eBay (http://www.ebay.co.uk/itm/Audi-1-9D-Brand-New-Turbocharger-717858-0009-717858-5009S-GT1749V-Turbo-/300782639966?_trksid=p2045573.m2042&_trkparms=aid%3D111000%26algo%3DREC.CURRENT%26ao%3 D1%26asc%3D27%26meid%3D4216648478820522034%26pid%3 D100033%26prg%3D1011%26rk%3D2%26sd%3D300709289224% 26)

Bearing in mind i can't go to oxford atm to collect the other one.:(

[slackda]

Got everything done and the car was idling just fine after a bump for the dead battery, left it running for about 20 mins and then tickled the accelerator, which I then ended up putting the engine into runaway, guess there was more oil locked up in the intercooler than I thought or my new turbo failed immediately... I think I managed to stall it in time but not sure, the exhaust blasted out a load of oil and now I can't get the car to start... Get engine stop light come on and oil pressure light but the oil levels are fine, next plan is to take the head off and check the valves arent smashed to pieces.. Anything else it might be?? sorry for lack of formatting , sent from phone.

[slackda]

Update timing had slipped by about 5 mm, car starts now and runs really rough but after about ten mins calms down. Thoughts on issue timing still slightly off( not run vcds) or other issues?

[slackda]

Update, Car was running rough at low RPM and when cold,

absolutely drinking fuel, VCDS was showing fault on EGR and Missfire on 3.

Ran for a test run to collect some more data did about 60 miles (on Motorway) averaging 38MPG.....down from 50MPG Average.... when loss of power and a ton of white smoke from the exhaust. not re run the VCDS to see if any faults registered, but upon clearing the miss-fire the first time it cam back.....

AA collected me a took me home convinced of a turbo Failure, not sure what could be wrong now no direct evidence i.e mayo lid or oil in the coolant to suggest Head leaking but the coolant levels had dropped from mid way between mid and max to below min...., going to remove the EGR and intake to give a good clean when the snow has cleared and go from there.