How to: 2.5 BPC turbo removal |
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CMP260
Groupie Joined: 02 Mar 12 Location: wales Status: Offline Points: 170 |
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Posted: 14 Nov 14 at 12:58 |
**THIS IS FOR 2.5 BPC MOTOR WITH WATER COOLED EGR AND CAST MANIFOLD** This procedure was on a late 2006 multivan -pictures to follow- you will need a long 10mm spline drive and a very long extension for your socket set This was done on my back under jack-stands -if you have a lift -lucky you!
Its hard to believe that this paragraph took me 15 minutes to write but about 30 hours to do the work. It must be said, trying to find hidden bolts and work out how to remove them after I found them, took most of the time so hopefully this will help others who haven't done it before. Next, putting it back together: I bought a 140mm long, 10mm spline on ebay.de -it made life a lot easier putting it back together. "M10 x L-140mm Vielzahn 12-Kant Stecknuss /Spline Steckschlüssel" Important: the turbo to manifold flange is not symmetrical, the flat tab on the gasket goes closest to the engine block. 2 sides of the flange are the same length, the 3rd side is shorter meaning the holes only match one way.
Edited by CMP260 - 28 Nov 14 at 17:32 |
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was a 2006 130 shuttle
now a 2006 174 multivan |
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jsola
Newbie Joined: 17 Jan 20 Status: Offline Points: 6 |
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And 6 years later... here comes my big thanks to you!
I however used another method. Mine is a 4motion and removing the DPF is not that easy. Even more, the transfer box would also have to be removed to gain the same access as you on the 2wd models. I felt so lazy just by thinking about it. So instead I detached the right suspension balljoint (two M14 spline bolts), the drive axis (remove the 32mm 12-side nut), the two noise insulators hanging from the wheel arch, detached antiroll bar from subframe. This makes enough clearance for the turbo to come out. Then you have make the turbo footprint smaller by removing the black plastic elbow in the fresh air intake of the turbo compressor. It is held in place by two 5mm Allen bolts. BTW I found it way easier to remove the spline bolt in the middle of the turbo, that which caused you so much pain, from the bonnet side. Looking from above with a little mirror and torch you will see it just on top of the oil bolt on top of the turbo core (more on this bolt in a moment). Grab the turbo with one hand from the bonnet, and slide it down until it rests somewhere. Then go to the right wheel... you can extract the turbo from the wheel arch! For all the rest, I followed your instructions and I am so thankful. One last thing: when reinstalling the turbo and before starting the engine, it is recommended that you prime it with clean oil. Just remove a screw on top of the turbo central core (18mm) and pour some new good quality engine oil in there. Be careful everything needs to be very clean, so make sure to have removed this bolt previously while on the bench with care, and cleaned up the bores so that no debris at all enters the oil section. Replace the cheap copper gasket. |
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jsola
Newbie Joined: 17 Jan 20 Status: Offline Points: 6 |
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Since I cannot edit my post, let me add a few details.
With the wheel arch method, you do not need to remove the engine mount at all. Ideally, only loosen the DPF from its rear support (two bolts). About the exhaust, on the 4motion moving the full exhaust assembly out of the way is not working, because it touches the rear drive axes and cannot move freely. Instead you would have to disassemble the joint close the central silencer, the joint on the DPF, and remove that section of exhaust tube. In my case this was easy. Overall this gives you enough access to work underneath -- indeed not as good as if you removed DPF, transfer box and engine mount, but this is a lot to remove! |
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T5 TDI
Vanorak Joined: 05 Nov 05 Status: Offline Points: 3687 |
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I'll add this to the 'How to do thread' jsola. Apologies to CMP260 that I seem to have missed it originally. Great to have it updated with the 4-motion info.
I really like to find real hands-on experience when I'm looking for info about a job I haven't done before and it's only the folks that actually bother to take the time to write it up and post pics that provide that. Edit- Just seen that it is already part of the 'How to do's but it is good to see that people still notice it/use it/add to it. Any corrections comments or updates are welcome on the How to do thread, if you have had a go, blab it out warts and all!
Edited by T5 TDI - 30 May 20 at 21:43 |
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2004 2.5 174
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baxmant5
Newbie Joined: 24 Aug 12 Location: Nottingham Status: Offline Points: 1 |
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Just another thanks to CMP260 for this write up.
I was really struggling to locate the last bolt holding the turbo onto the block. I'll go looking for a long 10mm spline to shift it.
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DIZZYT5
Not Quite Newbie Joined: 29 Feb 20 Location: East midlands Status: Offline Points: 20 |
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anyone got the turbo to block bolt torque settings?
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