2009 died on road today...not HPFP, Turbo....

2009 tdi died on road today....HPFP

Hi Everyone,

2009 TDI 6MT Loyal Edition 84,850 miles

Driving to doctor appointment, 1 mile from exit, got the "bong" accompanied by the Engine Fault Workshop warning and the flashing glow plug. Lost power, made a whining noise and died. Coasted off the freeway and stopped on the side of the road.

Called service manager near work. He said tow it in to a dealer and get it diagnosed. Probably HPFP.

Towed it in to dealer by my house. They will call me tonite or tomorrow.

Terry

Sorry to hear of your troubles.
When time permits, please post a detailed account in the "HPFP Failure" sticky, so others may benefit from your experience.

Dealer sais it is the Turbo. Asked for $3462 for r/r turbo.
They said it included 1339 for rebuild turbo, gaskets oil feed and return lines etc, labor 1300 tax 160.

Then offered it for 3116 (10% off)

Is this DIY? Any write up? is this a good deal?

Thanks
Terry

I have no idea about DIY. I'm sure others will weigh in, especially if you put "turbo failure" in your thread title.

Please have the moderator change your thread title, to avoid searching confusion.

What is your car's mileage?

What's their shop rate?

Would it really take more than 10 hours labor for the R&R?

Turbo comes out the bottom. Prepare to be on your back most of the job unless you have a lift. Its pretty buried but everything comes out and goes back in somewhat easily.
You also have to drop the center section of the subframe because the DPF is otherwise too large to fit through the tunnel.

You will also want to pull & clean the turbo outlet pipe and intercooler to make sure there is no debris from the compressor.

$1300 labor might be reasonable in California dollars, but I'd be suspicious of the "rebuilt" turbo part.

2009 6MT 84,500 miles.

So the dealer tells me it is the turbo.
3500 quote is not 2500 with VW participation.

Any DYI instructions?
Is it worth having the dealer do it?

I hear it has to come out the bottom and is pretty easy to do but the access and removal of all the stuff is hard???

Let me know, gotta tell them in the AM.

Thanks,
Terry

How did they determine its a turbo? Any codes?

Even if it is a turbo, 3500 seems very expensive.

I'll be replacing mine with a CR170 turbo this weekend hopefully. Drop the DPF, unbolt, remove, install new, install DPF. You could probably use the Rawtek how-to for removal and reinstall backwards if you're keeping it. I can't imagine it would be too difficult. I'm sure any independent shop familiar with these can do the job for around $2000-2500(turbo included)

Had a turbo failure 20K miles ago. First dealer that diagnosed it quoted me $3K, called another and they said that sounds too high and they'd do it for $2500. Had it towed to the other dealer. They put a new turbo in for this price. It has some minor change (adapter needed?) from the original turbo.

That turbo is way the F in the back of the engine, and there was no way I was gonna attempt that in my garage given that the engine has to be dropped a bit just to get the damn thing out.

Good luck. I got no assistance from VW customer care; loudly complained to them that a new $2500 turbo replacement every ~80K miles was BS; hopefully my replacement will last longer.

Engine doesn't exactly need to be "dropped" but pulling the dog bone mount bolts gets you a little bit of swing.

JFettig said:

I'll be replacing mine with a CR170 turbo this weekend hopefully. Drop the DPF, unbolt, remove, install new, install DPF. You could probably use the Rawtek how-to for removal and reinstall backwards if you're keeping it. I can't imagine it would be too difficult. I'm sure any independent shop familiar with these can do the job for around $2000-2500(turbo included)

Click to expand...

Plllleeeeeaaaaasssssseeeee do a write up! I'll be doing a similar swap soon too and there is no write up on removing the CR turbo anywhere.

But you're pretty much spot on with the work, you will also need to remove the EGR cooler to be able to get the turbo out.

Off topic, but since you're putting in a CR170 turbo did you make sure to get a new intake elbow? The CR140 and CR170 intake elbows are different.

I'll see what I can do about getting pictures and whatnot but I'm not making any promises.

The EGR cooler is coming out anyway, the LP EGR won't bolt onto the turbo. The CR170 HP EGR port is on the opposite end of the manifold so the HP EGR also can't be used. I am pretty sure i can get the turbo out the top rather than the bottom but I'll find out.

Yes, I got the new intake elbow.

JFettig said:

I'll be replacing mine with a CR170 turbo this weekend hopefully.

Click to expand...

Is there supposed to be much of a performance upgrade to the CR170 turbo? I'd be quite eager to find out how it reacts on a tuned Common Rail.

I'm expecting 190-210whp.

JFettig said:

I'm expecting 190-210whp.

Click to expand...

NOW YOUR TALKING!

My 03 Wagon I sold to buy my 09 had a 17/22 hybrid turbo on it and even through my 09 is tuned / rawtek'd - it just doesn't have that OOOOMPH that a larger turbo gives.

Keep me posted on how it goes stock vs. CR170 turbo! I want a turbo upgrade BAD!!

So I am having my car towed to another dealer who i have used before. They believe they can do it for 2500ish - VW customer care 30%.

Original dealer guy asked me why i was having it towed. I told him your bid of 3500 - with VW customer care was way to high, he lowered it another 300. I told him too late and not low enough.

Two examples of differences... 10 hours labor $1300 vs $1100
Turbo: $1339 vs $1059
and on from there....
Terry

yeah... I wouldnt go back to that dealer.... ever. They're gouging you on parts and labor...

My 2009 jetta sportswagen (tdi) went into limp mode two fridays ago, on the freeway...eventually started blowing blacksmoke, glowplug came on flashing...i had to have it towed and went to a mechanic who said it was a turbo rebuild kit which would cost about 1100....but suggested maybe taking it to a VW dealer and seeing what they could do, it was his opinion that this car shouldn't be experiencing these issues with 72k miles.

Went to a local VW and they say I need a new turbo, exhaust, downpipe, all costing around 5700....OUCH! I have not had the repairs done, for a few reasons, I'm working with VW on this...we'll see how this works out.

Do you know what the codes were?

The dealership reported no codes but before it was at the dealership it was at a mechanics where 2 codes were reported 000524 cylinder 3 injection timing & 000665 boost pressure regulation.

Get ye to a guru. There are still 2 guys in DFW. Steve & Brian.

steve ? <-- tdi guy?
brian?

VW said they'd cover 50%.....though I'm not sure if thats off the original quote of 5700 or the revised one they gave me saturday for around $3800...service manager is now hard to get a hold of :-/ there is also another quote they provided to VW corp...so not sure what that quote total was for ....i neglected to ask for that number when the rep was on the call..DOH!

Do you know what actually failed? Was there any noise? I had my actuator fail recently, granted it didnt throw any codes but I've got a tune and only drove it 2 miles w/o boost...

If they're hitting you for a new turbo and the actuator is the only isse there is no need for a new turbo, it can be replaced for $300 in parts (but a decent amount in labor). If the turbo is actually damaged then I can see it costing $3800 before the 50%.... $5700 is way too high...

Here is a similar tale:

http://forums.tdiclub.com/showthread.php?t=343424&highlight=Turbo

when I asked the "tech advisor" for codes or any evidence how they determined how the turbo failed he replied "you want me to write you a story?" i told him well i want you to tell me how you came to the conclusion i should pay you nearly 6k for my car so he sent me an email:

"Per your request...our tech found that the turbo failed and damaged the particulate filter. Upon inspection of turbo, the turbo impeller failed, not connected to the turbo shaft and engine oil entered into particulate filter. There were no fault codes found when checked for codes. I will further check other options on this repair on Monday, and call you with that."

well my quote went up to 8,191.13....but the dealership has decided to cover 70% .....generous yes....but just so frustrating i have to go through this with such a 'newish' car....i am breaking up with VW after this
03L-131-547-D 1 GASKET 7.70
03L-253-039-B 1 GASKET 9.60
03L-145-757-A 1 GASKET 7.00
1K0-254-706-LX 1 EXH.PIPE 1,100.00
1K0-253-115-T 1 GASKET 6.70
1K0-253-725 1 CLIP 49.00
1K0-253-115-AE 1 GASKET 7.40
1K0-253-725-B 2 CLIP 134.00
1K0-253-115-AE 1 GASKET 7.40
N-013-849-3 1 WASHER 1.02
071-115-562-C 1 FILTERELEM 9.00
G-052-195-1L 5 ENG.OIL 45.95
1K0-253-120 1 TUBE 245.00
03G-131-547-H 1 GASKET 3.50
1K0-253-725-E 1 CLIP 14.10
03L-253-056-X 1 EXMANTURBO 1,144.90
03L-145-771 1 OIL PIPE 76.00
N-909-788-01 1 SEAL 4.40
N-907-156-01 1 WASHER 2.10
N-908-946-01 11 NUT 9.90
03G-131-521-AT 1 PIPE 207.00
069-131-547-D 1 GASKET 7.70
03G-131-547-H 1 GASKET 3.50
1K0-998-262-AD 1 OXY SEN KT 263.00
076-906-051-A 2 SENSOR 190.00
03L-906-088-L 1 SENSOR 157.00
1K0-129-620-E 1 AIRFILTER 26.25
1K0-127-434-A 1 FILTERELEM 37.25
03L-145-757-Q 1 GASKET 5.90
3C0-129-646 1 SEAL 12.90
1K0-254-401-T 1 CATALYST 2,400.00
1K0-254-401-R 1 CATALYST 570.00
1K0-131-649 1 BRACKET 3.00
+ 1422 in labor

+ 1422 in labor

Click to expand...

That's high!

I'm in the middle of a CR turbo R&R to replace a failed actuator. The EGR filter canister is also broken. Fairly puzzled by this but the outlet side is completely free from the body. It was making a jingling noise when I pulled it in. I'm pretty sure this was causing it. The upper support nut was missing so I'm assuming someone had been in here before and just left the nut off since it's so hard to get to. Bad idea I guess.