Looks like the turbo went on my VRS (Original Post) so I'll be sourcing another one (probably eBay) and fitting it myself.

Now I know one end of a spanner from the other, and in the past have replaced cambelts, cylinder head gaskets and even whole cylinder heads when working on my previous cars.

I was planning on grabbing an old digital camera I have and taking a few snaps whilst I do it - mainly so I know how it goes back again, but also to stick together a quick 'How To' that might help people that want to undertake a similar job in the future.

I've never worked on a Turbocharged engine before and was just wondering if anyone has any hints or tips before I start?

I've no idea bud but would love a how to for something like this, hope ya get things sorted

Get the car up on some stands before you start as you'll need good access above and below.

You need to remove the EGR and then the inlet manifold before you can get to the exhaust manifold. Make sure you order enough gaskets for both.

Some penetrant spray is useful.

not totally relevant to this thread, but we always leave an engine to get HOT before removing manifold/turbo bolts, they come off a LOT easier that when they are cold.

Just wear some gloves

Access is tight, and yes you will need to access from above and below. Ideally you want new bolts/seals/gaskets and possibly a replacement oil feed pipe too.

Its worthwhile doing an oil change while you are at it.

Depending on how the old turbo failed, its worthwhile checking the I/C pipework etc for bits of turbo. If you are just getting overboost faults and limp mode/poor running, its possible the turbo just needs the variable vanes and mechanism cleaning, which is a doddle when you've got it off.

http://briskoda.net/general-car-chat/passat-requires-assembly/90969/

and

http://briskoda.net/maintenance-performance/de-coking-tdi-engine/89753/

Might be useful for things to do while you are at it!

Good luck

I've not worked on a turbo engine before either, but here's some tips I've read:

1. Make sure the oil feed to the turbo is clear- you might want to crank the engine on the starter (having disabled it from starting) to check you get oil.

2. Cleanliness when dealing with oil feeds.

and finally, TurboRemoval might help.

Cheers for the responses, I've got a couple of axle stands and a trolley jack so propping up the front isn't an issue.

I've taken off the EGR before to clean it out, so that shouldn't be an issue.

As for the other links - I was planning on just replacing the turbo, but looking at them I might take it off this weekend (if the weather picks up) and take the turbo to bits, see if I can clean it out and get it working myself.

Whilst I was at it I was going to clean up the pipes, intercooler and replace the oil (it's due now anyway).

Thanks again, I'll stick up a post in the technical guides section if I get anywhere.

It's dead simple mate - I managed to do it.

Just fiddly working around the back of the engine. IIRC removal of EGR/intake manifold (6mm allen head bolts IIRC). Removal of turbo downpipe.

Removal of the turbo with its integrated manifold below. Bring it all up. The junked one can be used as a manifold for adapting an even bigger turbo if needed (cutting off turbo housing and welding on a mating flange for a bigger non-hybrid OEM turbo).

Gaskets are metallic, can be re-used if not damaged (I did with mine).

Didn't need to jack mine up at all IIRC - but that was a while ago and I am getting scarily forgetful.....

HTH

Bas

Bas

A tech guide would be really useful if you do decide to remove and then refit the turbo. Might need to be doing this myself in the near future. Cheers.