Upgrading turbo to PD150 on BLT engine...shopping list

[michalko82]

As per title, what do I need to buy to be able to do this?   Swapping KKK to GT1749vb. Many say it's a straight swap, but some say lower boost pipe needs work, which oil feed pipe- seen varius shapes+ braided, gaskets etc.  Ideally from someone who has done it in the past, any advice is really appreciated.

Thank you,

Mike

[hutchysrs50]

It should be a straight swap apart from the egr pipe will need blanking off.

Boost pipes should be the same.

Oil feed + return should be the same.

 

When people say the boost people needs work, its possible they are meaning it needs to be clocked. Basically the housing could be sitting in a slightly different position so the pipes dont match up as easily. 

[faboka vrs]

Compressor bolts need removing and the compressor housing rotating 90 degrees then bolt back up.

[wja96]

I got mine from Xman750 and he arranged a Garrett on a BLT manifold so there was no issue with the EGR. You can do it with an ASZ manifold but it's much easier to blank off the EGR valve on the BLT manifold.

[vrs180]

Hi Mike.

 

I'm a (truck) mechanic and I fitted a brand new GT1749VB (PD160) to my wife's fabia vRS SE (BLT) in Sept 2015.

 

As such I can confirm that a GT1749VB does fit a BLT engine and will bolt straight up to the exhaust down pipe, oil drain and oil feed pipes, heat shields, lower support brkt etc all fit as per the original KKK.

 

One adjustment is required to the compressor housing (some refer to it as clocking), and all you do is slacken off the half dozen 6mm bolts, by approx one turn and rotate the compressor housing a few degrees until the outlet is in the exact same position as the KKK BV30-0016 you will have already removed then tighten the bolts back up.

 

The EGR cooler however will not refit so a blanking plate and gasket is required along with a genuine VAG heater hose (re route) kit , I got mine from Darkside. I got a litre of G13 just in case I lost coolant when swapping the pipes over but in the end none was needed. (Ask your mechanic to take care when fitting the heater hose kit, the new pipes require careful positioning to ensure they don't rub on the Tandem Pump housing).

 

As for gaskets, nuts etc, if you buy a new Garrett all the gaskets, studs and nuts are supplied with it (even comes with oil to prime the bearings with), the only additional gaskets and seals I recommend you get are the inlet manifold gasket, and a turbo outlet pipe seal/ "O" ring.

 

It goes without saying (but I'll say it anyway) renew the engine oil and filter and the air filter.

 

In addition to the above we chose to remove the redundant EGR  (just for reliability reasons, they all seem to end up leaking oil eventually), and fitted a Darkside EGR delete (very good quality Kit (in fact it looks too good bolted up to the OEM manifold and anti shudder valve)).

 

No adjustments are required to the actuator stop screw or rod length, only a custom remap required. 

 

Hope I've covered everything, if not, please ask.

 

Bill.      

[Kevin_Mc]

brilliant write-up, i'm bookmarking this thread for when i upgrade later in the year

[michalko82]

did you mean this turbo inlet pipe seal/ 'O' ring?

 

http://www.ebay.co.uk/itm/VW-Golf-MK4-Bora-1-9-TDI-Turbo-Inlet-Pipe-PD130-ASZ-PD150-ARL-1J0-129-627-D-/221522051645?hash=item3393be423d:g:0AEAAOSwT6pV1yWT

 

...and why do I need inlet manifold gasket?

 

cheers

Edited 8 January, 2016 by michalko82

[stevobeavo]

did you mean this turbo inlet pipe seal/ 'O' ring?

http://www.ebay.co.uk/itm/VW-Golf-MK4-Bora-1-9-TDI-Turbo-Inlet-Pipe-PD130-ASZ-PD150-ARL-1J0-129-627-D-/221522051645?hash=item3393be423d:g:0AEAAOSwT6pV1yWT

...and why do I need inlet manifold gasket?

cheers

Removing the inlet gives you more room and is essential if you bring the turbo out through the top.

The braided oil feed is a good investment as the solid pipe can break. Also means you can attack the feed to the turbo when it's off the car.

The braided feed can be had from Darkside.

Remember to pre lube the turbo with a bit of oil too. New exhaust and exhaust manifold nuts are a good idea too.

Ive done this myself a few times and it is pretty simple. Once you do it you'll be able to dona turbo swap in a few hours.

[michalko82]

I'll have it done by a garage, so I think they will remove it from the bottom... can the inlet manifold stay untouched?

[hutchysrs50]

Yep, I've removed plenty from the bottom alone. Drive shaft needs to be removed but that's it.

[michalko82]

looks like I've already bought a wrong oil feed pipe FFS.   it shows it's correct for the BLT engine but surely the turbo wants screw in type :((      but what's on the engine side?   What's the correct one for PD150 and BLT engine?

 

 

[stevobeavo]

On your old turbo where the oil feed screws onto can be undone and transferred over.

[michalko82]

oh great, so it not a f**k up then?

[hutchysrs50]

No it's fine.

Get new copper washers though