Replacing the Turbo - Polo 5DR 2005/6 AXR 1.9TDI
It's a great car, had an issue similar to this in the past and cost a dandy 3k plus... so thought I'd get into it myself this time, so far so good.
Day 1)
Symptoms:
Son driving to work and began belching copious amounts of white smoke from exhaust. Loss of power, he pulled over and called a tow truck and brought it home.
Hypothesis: Seals gone in turbo??
Observations:
* Engine fires up, you can smell the oil burning even at cold idle.
* Unclipped intercooler and 300ml of oil gushed out over my arm
Getting dirty:
Grabbed an oil tray and drained another 300ml and mopped up
Looked up the forum, realised the best approach was from underneath and disconnected the Inner CV (Evil 12 point bolts, not my first VW CV rodeo and only had to use vice grips once to extract one stripped bolt. I'll replace them with hex and get myself a 12 point too)
Wife's birthday out for dinner...
Day 2)
* Disconnected Exhaust flange from Turbo
* Began disconnecting Exhaust manifold
* Disconnected hoses and ducts
* Disconnected heat shield
* Disconnected Oil Supply Support clamp
* Disconnected Intake Manifold
* Removed cooland supply to EGR?? return
* Removed Intake Manifold.
* Dismantled Intake manifold & peripherals
* Soaking Intake manifold
* Cleaned Throttle body, EGR valve and manfold
* Scrub human of excess carbon deposits... What a messy job!
* Clean up nuts and bolts and organise.
Pics can be found here...
http://framepoet.org/mk5-polo-1-9-tdi-turbo-removal-and-repair/
NOTE: Two of the HEX bolts on the EGR cooler/manifold were "super tight"
Glad I did this on the bench, had to resort to vice grips and I do have good hex tools.
Turbo Type: BV39A-0019
Engine Type: AXR 1.9 TDI PS100 74kw
It's a great car, had an issue similar to this in the past and cost a dandy 3k plus... so thought I'd get into it myself this time, so far so good.
Day 1)
Symptoms:
Son driving to work and began belching copious amounts of white smoke from exhaust. Loss of power, he pulled over and called a tow truck and brought it home.
Hypothesis: Seals gone in turbo??
Observations:
* Engine fires up, you can smell the oil burning even at cold idle.
* Unclipped intercooler and 300ml of oil gushed out over my arm
Getting dirty:
Grabbed an oil tray and drained another 300ml and mopped up
Looked up the forum, realised the best approach was from underneath and disconnected the Inner CV (Evil 12 point bolts, not my first VW CV rodeo and only had to use vice grips once to extract one stripped bolt. I'll replace them with hex and get myself a 12 point too)
Wife's birthday out for dinner...
Day 2)
* Disconnected Exhaust flange from Turbo
* Began disconnecting Exhaust manifold
* Disconnected hoses and ducts
* Disconnected heat shield
* Disconnected Oil Supply Support clamp
* Disconnected Intake Manifold
* Removed cooland supply to EGR?? return
* Removed Intake Manifold.
* Dismantled Intake manifold & peripherals
* Soaking Intake manifold
* Cleaned Throttle body, EGR valve and manfold
* Scrub human of excess carbon deposits... What a messy job!
* Clean up nuts and bolts and organise.
Pics can be found here...
http://framepoet.org/mk5-polo-1-9-tdi-turbo-removal-and-repair/
NOTE: Two of the HEX bolts on the EGR cooler/manifold were "super tight"
Glad I did this on the bench, had to resort to vice grips and I do have good hex tools.
Turbo Type: BV39A-0019
Engine Type: AXR 1.9 TDI PS100 74kw
Last edited: