MK3+ EA211 1.2TSI Turbo Core Replacement / Turbo Refurbishment

Upon deciding to keep my Mk3 Fabia until its death, I've decided I want some more power from my EA211 1.2TSI 110 and as such needed a larger turbo.

This very handy guide linked below by @FabiaGonzales will tell you everything, except self refurbishment, that you need to know about fitting a larger turbocharger from the bigger sister engine 1.4tsi; https://www.briskoda.net/forums/topic/481489-turbo-swap-choices-for-ea211-12-tsi/

Now, I decided that I didn't want to fork out for a brand new turbocharger, and I didn't want to ship a turbo off to Europe for refurbishment, so I decided I'd do it myself. With limited resources online about how to do this, it was a slow job whilst I made sure I did it correctly. However, Hopefully this guide will be of use to anybody looking to replace the turbocharger core on their EA211 1.2 or 1.4TSI.

I picked up a used turbo (04E 145 721B) from ebay for £87. Quite a steal if you ask me. Now, The turbo itself seemed fine, but i was not about to risk it exploding in my engine, so I picked up a new turbocharger core (the most important part) from London-2020-TurboShop for £100. This will come with a balancing sheet to put your mind at ease, and is also supposedly an upgrade from OEM as its wheel is lighter - whether or not actually proves real performance differences im not sure.

You dont need many tools for this job, namely;

• T30 Torx bit

• 4mm Hex bit

• 10mm socket

• WD40 / GT85

• Carb Cleaner

• a few rags

• Nickel Grease

• Exhaust Assembly Paste

PLEASE NOTE: I am in no way a trained super mechanic or turbocharger extraordinaire, this guide is simply how I completed the job, and is in no way the definite, correct method. If you undertake this job, you do so at your own risk (Like I did), and I am not responsible for any damage caused to anything. If you are not mechanically sound, I would suggest letting professionals deal with the job. Turbochargers can spin up to speeds in the hundreds of thousands of RPM range, and an imbalance can destroy both the turbocharger, and your engine.

Part one

First step is to free off the actuator pivot. This may not apply to everybody. I found the turbo I bought had seized on the pivot, a common issue. If you can extend the actuator and thus open the wastegate, you're fine.

If, however, you can't, with your hands, extend the actuator then its seized. You'll need to just go to town with some WD40 or GT85 and a wire brush to try and wiggle it free.

Firstly, Remove the circlip from the pin. Then, remove the two T30 screws holding the actuator to the turbocharger. You should then be able to push the pin DOWN and out of the arm. You can see this in the image above, on the right. Like a see-saw, this will raise the actuator away from the turbo inlet side.

Now that that's done I gave the actuator pin and wastegate arm a good clean, ready to be reinstalled with some nickel grease later.

Part two

After removing the actuator from the turbo, I then proceeded to remove the exhaust side from the core. First job is to remove the clamp that holds the core to the exhaust side. Just use your 10mm socket to loosen off the bolt, then remove the clamp. You should then just be able to pull away the exhaust side with ease.

Notice in the photo what i am pointing to. There is a little notch on the exhaust side that fits in to a groove on the turbo core. This is to ensure correct orientation when fitting.

Excellent, Now we're ready to remove the core from the inlet side. Before doing so, please take images of the correct orientation of your core, as there is no groove to align it properly on this side.

Remove the 3x 4mm hex bolts from the face of the core. Once removed, you should just be able to pull the core off. It seems there was a paste used to seal this side, so I had to slightly twist and wiggle the core to break this, then pull it off.

Now, your turbo should be fully disassembled into the 3 parts. I now cleaned up the cast parts. I used carb cleaner for the exhaust side and it did look slightly less black afterwards. I avoided using a wire brush on any internal, smooth parts, as I didnt want to introduce imperfections to the surface.

Now, reassembly is mostly the same but in reverse order. Be VERY CAREFUL with your new core as it is very delicate. I applied some Exhaust Assembly Paste around the outer lip of the core (The surface that sits against the inlet side) before fitting back and bolting down. Just ensure that if any exhaust assembly paste sits ON or inside the lip you wipe this off. We only want it sitting outside, and not smushing inside when you bolt the core down.

Once completed, pop the exhaust side back on, minding the core & remembering to align the notch. Then, Tighten the clamp back down to hold it in place.

Lastly we have to fit the actuator again. I applied Nickel grease to the pin and arm hole to ensure effective movement and to prevent it from seizing in the future. Then just bolt it back in.

Hooray!

Now you've completed the refurb, and your turbo should look beautiful, like the below.

I hope this guide has helped, if anybody has any better tips/guidance feel free to leave them in the comments. This is by no means the "correct" way to do this job, just how I did it!


Lew

Edited 26 March, 20251 yr by lewiswal47