POP! Blown turbo? 1.9 TDI 130

[CupraLew89]

Hi all,

Before anyone asks, yes i have searched the forum for this problem and the reason for the post is that I cant find any popped or disconnected hoses (i hope i am looking in the right place)

Long story short - turned into my road two days ago accelerated and had a pop from under the bonnet followed by a serious lack of power. Pretty much figured it was the turbo. Read a lot of threads about intercooler pipes etc popping off as this is common so hoped for the best. Jacked the car up but couldnt find anything. disconnected the pipe that connected the turbo to the intercooler and reconnected all ok. the other end on the intercooler is connected and clips still in place.

I checked the rearview at the time of the pop and there was smoke, but just looked like diesel smoke not plumes of black smoke as some other post have said. Luckily only a minute drive to my house but noticed there was some strange noises and the owl sound from the turbo which is very noticeable.

Checked the oil level and its all still in the sump. Started the car up after reconnecting the intercooler pipe to see if it resolved it and engine ticks over fine, no smoke from the exhaust, but turbo is very noisy and owl noise when increasing the RPM. I havent driven the car since dumping it outside my house.

Im guessing the turbo has popped its clogs but any other advice on pipes to check etc would be appreciated


FYI - 2003 1.9 TDI ASZ car is not remapped, only 78K

 

[R3k1355]

Still sounds like you've blown a pipe off somewhere.

The two that connect directly to the intercooler are the most common to pop off, and annoyingly quite hard to see.

 

[CupraLew89]

Thank mate, I've literally just taken the bottom intercooler pipe off which was secure, some oil in there. I'm still trying to access the top intercooler pipe as its behind the headlight. Turbo to intercooler pipework seems fine though.

I will keep you posted.

Thanks

 

[auds2]

Other pipe to go, and ive seen it a few times now is the one from that pancake pipe to the coldside of the turbo.
Its a tightish bend in it and seen it split several times on the outside of the bent.

 

[CupraLew89]

Just taken the top intercooler pipe off behind the headlight, it was all secured and no splits in it. Also found a tiny piece of metal in the top intercooler pipe, guessing thats a bad sign

auds2 - I assume you are talking about the inlet pipe from the air filter to the turbo? This is metal in my case, ther might be small bit of rubber coupling it to the actual turbo though i will investigate

 

[auds2]

No buddy, i mean the one from the intercooler on the driversside of the car, under the brake servo area ish.

Im guessing metal in the pipe is probs going to be bits of turbo impeller but you never know till you have a look

 

[CupraLew89]

Ah, yeah took the inlet pipe off and got my camera in there. the turbo impeller is completely mashed beyond all doubt so the turbo is history. Just wondering now whether its worth replacing as obviously bits of turbo metal are floating around the system? The only good bit is that i didnt drive more than a few hundred meters before dumping it outside my house. I have started it up a few times since then

Advice is much appreciated

Sad faces all round

 

[R3k1355]

Take all the pipework off, see if any got as far as the intake maifold.

Chances are it was all caught before then, it's probably wise to get replacement hoses and an intercooler as you don't know what bits and pieces of shite will be stuck in them now.
Worth dropping the oil out of the sump and checking that, just on the off chance the bearings fell apart and got squirted down the oil return.

You'll probably get away with just a replacement turbo, but it's always a good idea to check everything first.

 

[CupraLew89]

Cheers yes makes sense. I found one shard of metal the top side of the intercooler but it would have to get through the other pipes and EGR yet so fingers crossed. Good advice on the intercooler and oil change. I will get to work on checking up to the manifold, then getting the old turbo out and sourcing a replacement unit.

Thanks for all the help

 

[auds2]

^^^^^^^^^^WHAT R3k1355 said ^^^^^^^^^^

Best be safe than sorry mate

 

[CupraLew89]

Just a quick update on this thread.

I took the whole turbo system apart last weekend, got the turbo, intercooler, EGR, intake manifold and all pipework off the car. Thoroughly cleaned everything with carb cleaner (aside from the busted turbo). I found one shard of metal top-side of the intercooler and a whole heap of metal shavings from the turbo was laying in the bottom of the intercooler. The intake manifold and EGR were caked up so I cleaned them up as best I could. I didnt find any more metal parts lodged in the cakey oily mix.

I managed to get hold of a replacement used turbo from a golf PD 130 as it looked like what i needed. However when it arrived I found out it was a Garrett GT1749VA and my old one was a KKK turbo. I knew that these turbos were interchangeable and heard on the forums that Garrett was a better unit anyway. The only problem was that the outlet from the compressor housing was in a different position to my old turbo. Then I read up that the turbo can be "clocked" to match the correct position so managed to do this.

I fitted the turbo today and reconnected everything. The car started up fine and I let it tick over to get the oil moving took it for a spin and it seemed to boost well. The same, if not better than before with no odd noises. Only time will tell but at the moment a positive result.

Oil change is next on the list with new filter and sump (might get a magnetic one)

Thanks for the help, hopefully someone else can benefit from my experiences

 

[stace11022]

Wow talk about being in the same boat.....

I own a 2007 Ibiza Fr pd130
Mod's -
Stage 2 Revo remap 173bhp (mapped @60k car currently on 102k)
Organic clutch
Turbo back Milltek exhaust
Seat sport frontmount intercooler

My story -
Driving home a week ago the car was warm (Already driven 15 miles)
I put my foot in second gear and pop, it was like a boost hose had popped off and there was a big cloud of black smoke out the back.
within 20 meters of the pop the engine started to sound very knocky (Not sure if that's even a word...lol)
Anyway I drove it home ..about a quarter of a mile and noticed there was remnants of the hot side turbo compressor wheel rattling around in my back box.
I managed to find the time to strip the turbo off and both compressor wheels have pretty much exploded
and gone everywhere ...I ripped the head off and cylinders 3/4 are hammered with a piece of impeller.
Ive had my mate whos an engine builder look at it to see if its save able and he said yes,...Phew

 

[stace11022]

So far

Head skimmed valves replaced guides and stems sorted ...£150 Friends rates
I cut the cambelt off ...in a fit of rage ...(only been on the car 6k) new belt ...pump ...tensioner £80
Head gasket set £50
Head bolts ..£40

Ive cleaned the egr ..inlet ..boost pipes ..I'm yet to clean the intercooler...not had time

My only issue is im running out of cash and yet to find a replacement turbo..
Is there a Bolt on upgrage like off a pd 150 or pd160/pd170

 

[CupraLew89]

Damn, that sounds a bit more serious than mine, I hope it works out. When I looked at my turbo it looked like the shaft had unscrewed itself or something. But mine was only on the compressor impellor side( If that's even the right word) the exhaust side was all ok. Luckily I didn't have far to drive it back home, maybe that saved me. Fingers crossed.

 

[CupraLew89]

A bolt on turbo upgrade is the GT1749VB from a PD150. Apparently they can push a bit more boost. Should get 200hp or a bit less from one of those. Based on the research that I did. Others would say get a hybrid turbo but that's a lot of extra cash. Someone else will probably know more. I don't know if the GT1749VB will need to have the turbo compressor housing clocked like mine did.

 

[stace11022]

Hi,
Cheers for the reply Cupralew89

When I inspected the turbo both compressors were destroyed and by the look of it both shafts have snapped just before the seals ...?(no oil loss and seals still in place )

As regards to the GT1749VB im sure I can "clock it" myself, Ill blank the EGR off but do I need any other pipes to make it fit ....?

 

[CupraLew89]

Hi,

I found this page about the differences between GT1749VA (PD 130) and GT1749VB (PD 150) turbos.

http://forums.tdiclub.com/showthread.php?t=154079

I had a KKK turbo fitted to mine originally and now I have the GT1749VA used in other PD 130 applications. Mine fitted on easily, I just needed to clock the turbo housing to get the outlet to the correct position and it fitted with the same pipework. It sounds like the housing on the GT1749VA and VB is the same just the internals are a bit different. So I assume that if my old KKK is the same fitment as the GT1749VA... and the VB is same as the VA it should fit as well. Thats my logic anyway, but its open to interpretation. I would imagine another remap would be in order to get the full benefit of the upgrade turbo.

stace11022 was your old turbo a KKK one out of interest? Sounds like a similar problem to mine.

 

[stace11022]

Yes it was a KKK turbo ..
I've managed to find a replacement kkk, so all ive got to do now is to rebuild everything .