Nice one. Good luck with the cleaning of it :-)

turbo all nice and clean very happy with that- it was seized solid with rust / carbon.. :S although completely mullered the three t20 torx :'( need to go down the local hardware shop first thing to try and find some kinda replacements the inlet manifold's having a good soak now to try and clear some of the crud out- its in a bad way :S egr valve has got what looks like a huge piece of 'plastic' jammed in there... im hoping its carbon- quite concerned by that tho..

replaced snapped downpipe stud

really looking forward to getting this back together tomorrow, and see what the difference is

just got the good news from the vw specialist....the wastegate on the turbo is knackered, looking at a rebuild or a new turbo unit. Phoned the dealer i bought it off, who will thankfully stand over it and get it fixed this week.

if you dont mind getting your hands 'very' dirt, it isnt too bad a job to get the turbo off and strip down.. plus there are plenty of how to's on the forum to guide you through the process

it took me about 2hrs to get the turbo off- some bolts (oil drain and mounting bracket ) have to be un done from underneath, but the rest is done from above..

i took plenty of photos while stripping it down, just to make sure that it went back the right way.. ive gotta sorce 3 new t20 torx bolts tomorrow and hopefully should be back on the road by miud afternoon

certainly better than paying to have someone replace your turbo :S

thankfully i dont have to get my hands dirty on this one, left the car with the dealer on wednesday morning. Didnt look happy but tough, he gave me three months warranty on the motor. He is getting a local firm who do turbo recons and ecu remaps to sort it out, either a repair or replacement. Hoping for a replacement personally, get plenty of use out of a new unit. Hope to hear later this morning as to how its going...

thankfully i dont have to get my hands dirty on this one, left the car with the dealer on wednesday morning. Didnt look happy but tough, he gave me three months warranty on the motor. He is getting a local firm who do turbo recons and ecu remaps to sort it out, either a repair or replacement. Hoping for a replacement personally, get plenty of use out of a new unit. Hope to hear later this morning as to how its going...

result

got the car back today. Turbo stripped, cleaned, wastegate sorted and a brand new boost valve fitted (even got an oilchange and air filter thrown in as an apology for the delay)...result!! Going like a dream now.hope it lasts.

got the car back today. Turbo stripped, cleaned, wastegate sorted and a brand new boost valve fitted (even got an oilchange and air filter thrown in as an apology for the delay)...result!! Going like a dream now.hope it lasts.

Hi - I have a 2002 Octavia with 50K on the clock. In the past five years it has barely done 1000miles between MOTs. I got an Engineer to test it before I got it and it is in near showroom condition. HOWEVER - with the whole family in it it seems to drop off boost when accelerating hard and I have attached graphs showing the acellerator on full but the MAF flow dropping off and the manifold pressure dropping. I am not getting any engine codes. The lack of power persists until the engine is stopped a bit like limp home mode. I am a bit concerned about the manifold presure climbing to 260Kpa! Googling what is normal for manifold pressure is failing to come up with anything. The drop in MAF from 105 to 40 would explain a large drop in power (I did find Power is proportional to MAF value about 0.8?) I would guess that with this low milage old car I have a very sooty EGR and Turbo.

So....

1) Any comments on the graphs? What is a normal manifold pressure?

2) Haynes manual - taking EGR and Turbo off...

2a) do you really need to take the RHS drive shaft off? And have to take exhaust manifold off engine with Turbo.

2b) Anyone volunteer a gasket list to do the job - presumably dealer parts.

Thanks Dave

Some wierd figures there.

You have a peak pressure of 262 kpa which I believe is 38psi?

I know the Fabia VRS with the 130bhp engine peaks at 18psi standard and is maxed out around 25psi so this sounds like a lot on an ALH engine (90bhp?), I'd assume the max pressure on that engine would be way less than 18psi.

You can calc power by dividing the MAF value by 0.8 so your power according to the first graph was 128bhp and the second one about 112bhp, again wrong if you have a 90bhp engine but I've no idea if this calculation is supposed to be used on diesels (it works ok on petrols)

If you had the sticky vanes problem it would normally throw an overboost fault code. Do you know for sure that your engine is variable vane turbo and not the older wastegated type as the earlier 90bhp ones were?

Did the diagnostics tool you used to get those graphs have an option to set it up for a diesel engine? I remember my Liquid Gauge had to be set up specially for a TDI otherwise I got spurious MAF readings.

Try disconnecting the MAF and see if it runs better. MAF readings really only make sense at WOT. The reference value is at 3000rpm.

I cleared my limp mode using this, hope it of help to someone.

My link

Only thing is you dont feel the boost in power they say, but it does run better and rev smoother

FYI my TDI has done 130,000 miles and was well worth the money.

Edited 13 March, 201214 yr by DSS199

Hi - Looking down the back of the engine as best I can it all looks like a Variable Vane Turbo with the actuator part of the turbo. This artical on an ALH shows most of the parts I can see http://www.myturbodi...-TDI-engine.htm  

I put the scanner on again with engine off and MAP is showing 101 kpa which is about atmosperic pressure. So areading of 260 is pretty incredible. MAF on the idling engine is showing about 12g/s. I have sent some diagnostics to EngineCheck support to see if everythign is reading ok.

So it looks as if I need to get it all off and clean it! Unless Although finding a turbo specialist near Redditch UK is looking a viable option - job looks back breaking and knuckle busting with lots of rusted up studs.

Thinking about it, if it's the same as VAG-Com it adds atomspheric pressure to the manifold pressure reading so your actual manifold pressure would be 260-101=159 which is 23psi, a little bit more reasonable but still at the maximum limit of the turbo. So it could be overboosting to that level because of the variable vane problem then going into limp mode.

I'm sure there was someone mentioned on here who does a mobile TDI turbo cleaning service, but can't find the thread for the life of me. I did see a figure of £250 quoted in a recent thread for a normal garage or dealer to remove and clean the turbo.

EDIT: R-Tech do it for £235, based at Hinckley, Leicestershire so only about 35 miles from you