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Turbo removal on ALH engine VW Jetta TDI, VW Golf TDI, or New Beetle TDI, 1998

Time:2012-09-29 06:08Turbochargers information Click:

Turbo tdi remove bad ALH

Turbo removal turbo replacement on ALH engine, BEW engine similar

difficulty: 2/5
back to 1000q: mk4 FAQ and "how to" list
back to 1000q: mk4 pumpe duse index and "how to" list

Introduction

This article shows turbo removal on an ALH engine Jetta/Golf.  New Beetle is similar.  

Although the BEW is slightly different, the procedure is similar, see your factory service manual for the differences.  Many times low power or the turbo cutting out is misdiagnosed as a bad turbo.  If you have these symptoms, see 1000q: limp mode diagnosis and 1000q: constant low power or can't rev.  If you want to swap the turbo to make more power, see 1000q: TDI turbo upgrade chart.  Difficulty is only rated 2/5 because it's not technically difficult and doesn't require any special tools other than the normal shop tools.  However, it's time consuming and you might run into complications so be prepared.

The easiest way to remove the turbo is from above because of clearance.  The turbo and exhaust manifold are 1 piece.  This also gives you the chance to clean the intake manifold of carbon.  It might be faster to remove the turbo from below but you would have to remove the passenger side driveshaft.  There's also less clearance and there'll be lots of rusty chips falling onto you so I suggest removal from above, as described in this article.  Always wear eye protection, note all cautions in your factory service manual, and see the TOS Agreement for the legal disclaimer.

ALH engine is 1998-2003, BEW engine is 2004-2006 TDI

Secondary writeup: 1000q turbo removal on ALH engine, writeup 2  (mirrored document from TDIinnovations of TX)

Parts/Tools

Note: service manual says in one place to always replace BEW engine's downpipe nuts, in another place it has no such note, ALH also has no such note.  While you can reuse the nuts if they are in good condition, good practice is to buy new self locking nuts.  You're also supposed to use new exhaust gaskets but if you're missing one they can be reused.  I wouldn't since they're cheap and replacement would require you to remove the turbo again.

ALH engine (1998-2003 ) parts

1 turbo oil line VW# 038 145 771 d
downpipe gasket (always replace) VW# 3a0 253 115
exhaust manifold gaskets (always replace) VW# 028 129 589 b
3x downpipe nuts VW# n 908 946 01
oil union crush washer  (always replace)

BEW engine (2004-2006 mk4) parts

1 turbo oil line VW# 038 145 771 aa or VW# 038 145 771 n
turbo oil line union and crush washer (optional) VW# 045 115 677 a and n 013 812 3
downpipe gasket (always replace) VW# 3a0 253 115
exhaust manifold gaskets (always replace) VW# 028 129 589 b
3x downpipe nuts VW# n 908 946 01
oil union crush washer  (always replace)

5, 6mm allen sockets
10, 12, 13mm sockets + wrench
PB Blaster or Liquid wrench
remote cable operated spring clamp pliers

Procedure

Raise the front of the car, chock the rear wheels, rest the car on jack stands, make sure the car is safe and secure before getting under it at all!

Remove the intake manifold.  If you have a BEW pumpe duse engine, also see 1000q: BRM intake manifold removal.  The BEW engine intake manifold is different but the exhaust manifold and turbo is similar to ALH engine and it will give you a rough idea of what to do.  It's not required to remove the EGR cooler - just remove its 3x bolts and tie the cooler out of the way.  Also disconnect the VNT actuator's vacuum line from the N75 solenoid.  I suggest removing it at the solenoid to avoid disturbing the bottom end.

Spray all the exhaust manifold nuts with PB Blaster or liquid wrench penetrating lubricant.  Pictured below is the exhaust manifold removed so you can picture where the exhaust manifold nuts are.  Spray some on the 2x heat shield nuts.  Penetrating lubricant will help eat rust, loosen them, and really help prevent stripping.  Also put a few drops on top of the oil line union.  This will help prevent twisting of the oil feed line when you remove it later.

The black ball stud on the intake manifold is the "easy pop off" engine cover mod.  It replaces the studs/nuts with a pop off connector.  See 1000q: pop off engine cover to see more info.

Remove the turbo intake hardpipe (1x 10mm bolt on the intake manifold and 1x allen head bolt holding the other bracket as detailed in the intake manifold removal article).  Remove the turbo outlet-intercooler piping.  Use the remote operated spring clamp pliers to release the spring clamps at the turbo and intercooler.  1x 10mm nut holds the intercooler piping to the body.  

An ALH turbo is shown - to release the BEW engine hoses, pull the quick connect clip out and the tabs that hold the hose will be released.

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