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How to: AXD Manifold and Turbo Removal |
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Liquidfreak 
Yardie 
Joined: 25 Feb 08 Location: Cornwall Status: Offline Points: 839 |
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 Posted: 30 Dec 10 at 15:53 |
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Please Please PLEASE can someone tell me how the fuck the clamp comes off in photo 3 and 3.1. It is driving me insane!!!
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2004 VW T5 Panel Van T30 2.5 130 AXD Engine
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T5 TDI
Vanorak 
Joined: 05 Nov 05 Status: Offline Points: 3687 |
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Posted: 30 Dec 10 at 17:37 |
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The end of the exhaust is flared, that rests against a corresponding bulge on the turbo. Once the allen bolt is out you will need to lever the clamp off if wriggling the exhaust backwards and forwards doesn't work. Try soaking it in penetrating oil and them tapping a large old screwdriver under the clamp. And keep wiggling. When it's ready it'll just go.
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2004 2.5 174
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Liquidfreak
Yardie
Joined: 25 Feb 08 Location: Cornwall Status: Offline Points: 839 |
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Posted: 30 Dec 10 at 18:42 |
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So is the clamp two pieces then? I mean, the outer 'clamp' and then the inner V/U shaped bit which holds the exhaust to the turbo. Looks to me like it is spot welded together.
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2004 VW T5 Panel Van T30 2.5 130 AXD Engine
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T5 TDI
Vanorak
Joined: 05 Nov 05 Status: Offline Points: 3687 |
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Posted: 30 Dec 10 at 19:14 |
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No it's in one piece, it's just that although you have undone the allen bolt, the inner pieces (spot welded to the clamp as you say) are still stuck fast around the exhaust to turbo joint.
It's best to buy a new clamp anyway so if you aren't sure the new clamp will make things clearer.
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2004 2.5 174
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Liquidfreak
Yardie
Joined: 25 Feb 08 Location: Cornwall Status: Offline Points: 839 |
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Posted: 30 Dec 10 at 20:43 |
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Right-o. Think I shall put it all back together and drop it in a MIJ Exhausts in Jan when I am up there, get a SS one instead.
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2004 VW T5 Panel Van T30 2.5 130 AXD Engine
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Liquidfreak
Yardie
Joined: 25 Feb 08 Location: Cornwall Status: Offline Points: 839 |
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Posted: 02 Jan 11 at 22:44 |
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This thread is as far as I am taking it, if anyone wants to continue it then be my guest. Sorry it wasn't a complete walkthrough - more so for me as now I need to pay to get it fixed!
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2004 VW T5 Panel Van T30 2.5 130 AXD Engine
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Kitawagon
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Joined: 26 Jun 10 Location: Bath Status: Offline Points: 168 |
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Posted: 21 Sep 11 at 13:18 |
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Coming back to this ole manifold chestnut. It seems PPT might be gearing up to being able to sell their alternative. Here's hoping..
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2004 LWB 2.5 AXD 130hp, K&N Filter, Allard EGR Pipe and Oil Breather Tank....
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energysolutions
Vanorak
Joined: 02 Dec 08 Location: Earth (For Now) Status: Offline Points: 3684 |
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Posted: 21 Sep 11 at 23:06 |
Dont hold your breath, I spoke with them initially over a year ago and they began the development process shortly after (aided by "mistadave`s" contribution of a donor manifold) I spoke with PPT again around 3 weeks ago after leaving my van in for a service they found the manifold was fecked and I required a replacement, they said that they had one manufactured and it was now in the testing phase but reading between the lines I dont expect the finished article to be available any time soon Shame really as I had then had no option but to shell out ~£300+VAT to VW for another genuine manifold which clearly isnt fit for purpose, simply because there isnt an alternative Between that, a service, brake pads all round, another broken rear spring (unbelieveable), drop links (again) and new shocks all round etc etc my "simple service" became a £1500 nightmare |
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!!Never Eat Yellow Snow!!
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Kitawagon
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Joined: 26 Jun 10 Location: Bath Status: Offline Points: 168 |
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Posted: 22 Sep 11 at 13:06 |
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Breath held! Please oh please PPT deliver the goods. On a related note I also took delivery of the German Fleabay Turbo to manifold gasket. I'll take some pics and post. My ideal situation is for PPT to have their manifold ready by end of Sept, take delivery, book the van in to local indie, have them remove the turbo and crappy ole excuse for manifold, send turbo off for servicing, then have new PPT manifold, serviced turbo and fleabay gasket refitted (not sure if i'd need the gasket then but it seems a good idea?).
Wishful thinking, but I can but hope.. |
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2004 LWB 2.5 AXD 130hp, K&N Filter, Allard EGR Pipe and Oil Breather Tank....
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Liquidfreak
Yardie
Joined: 25 Feb 08 Location: Cornwall Status: Offline Points: 839 |
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Posted: 11 Oct 11 at 23:54 |
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Any further news on the PPT manifold?
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2004 VW T5 Panel Van T30 2.5 130 AXD Engine
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Kitawagon
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Joined: 26 Jun 10 Location: Bath Status: Offline Points: 168 |
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Posted: 12 Oct 11 at 07:20 |
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Sorry, I should have tidied this up. In short, the answer is nothing definate. Jason at PPT suggested a further 2 months (and that was three weeks ago), therefore we could be in luck in 5 weeks from now, say middle of November? Can I suggest that anyone who is wanting a replacement perhaps give PPT a call so they know the numbers of people that are keen? This may provide the additional impetus needed?
http://www.performancepipesandtuning.com/contact.php Tel: 01507 611088 Cheers Edited by Kitawagon - 12 Oct 11 at 07:21 |
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2004 LWB 2.5 AXD 130hp, K&N Filter, Allard EGR Pipe and Oil Breather Tank....
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Kitawagon
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Posted: 12 Oct 11 at 07:56 |
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On a related note, see the following pictures for the German fleabay ordered exhaust manifold to turbo joint. I'm hoping the fact that is has raised edges around the central hole will mean it will do the job better than perhaps a typically flat metal gasket? Thoughts?
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2004 LWB 2.5 AXD 130hp, K&N Filter, Allard EGR Pipe and Oil Breather Tank....
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The Transporter
Vanorak
Joined: 08 Nov 05 Status: Offline Points: 1012 |
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Posted: 13 Oct 11 at 09:35 |
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That ain't gonna help you much if like mine, the entire flange fell off the manifold.....
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2004 174bhp AXE engine..... Belligerence has been confirmed.
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Kitawagon
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Posted: 13 Oct 11 at 12:32 |
That's true  . I hope not, but there is no way to know until it's out! |
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2004 LWB 2.5 AXD 130hp, K&N Filter, Allard EGR Pipe and Oil Breather Tank....
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Liquidfreak
Yardie
Joined: 25 Feb 08 Location: Cornwall Status: Offline Points: 839 |
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Posted: 13 Oct 11 at 15:38 |
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Do you know if the EGR connection has been blanked on the new manifold? My one made it's own modification about 3 weeks ago where it sheared off - fixed with a coke can to get me home.
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2004 VW T5 Panel Van T30 2.5 130 AXD Engine
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Kitawagon
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Posted: 14 Oct 11 at 13:16 |
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I'm 99% certain the PPT one will have no EGR spout..
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2004 LWB 2.5 AXD 130hp, K&N Filter, Allard EGR Pipe and Oil Breather Tank....
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T5 TDI
Vanorak
Joined: 05 Nov 05 Status: Offline Points: 3687 |
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Posted: 14 Oct 11 at 21:51 |
Could have done one of those when I did mine. It looks like a crushable ring on the gasket which gives an extra thick seal when it's flattened. It's the same idea as the triangular one that seals the oil supply/return on the turbo where it's bolted to the block. Edited by T5 TDI - 14 Oct 11 at 21:53 |
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2004 2.5 174
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Liquidfreak
Yardie
Joined: 25 Feb 08 Location: Cornwall Status: Offline Points: 839 |
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Posted: 15 Oct 11 at 18:29 |
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How much was that Kitawagon? do you have a link?
Cheers
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2004 VW T5 Panel Van T30 2.5 130 AXD Engine
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Kitawagon
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Posted: 15 Oct 11 at 21:42 |
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So here's the german ebay link:
http://www.ebay.de/itm/Abgaskrummer-Turbolader-Krummer-Dichtung-VW-T5-2-5-TDI-AXD-R5K-/230681305626?pt=DE_Autoteile&hash=item35b5ad621a But now I'm confused as there is also this lot? I'm guessing the other two are one for the turbo oil seal and the other for the exhaust clamping to the turbo? I wasn't aware the turbo to exhaust pipe was also at risk of leaking? http://www.ebay.de/itm/Turbolader-Dichtsatz-VW-T5-2-5TDI-96KW-BNZ-R5K-AXD-/230678084885?pt=DE_Autoteile&hash=item35b57c3d15 As I couldn't figure out how to register on german ebay, I simply emailed him at: Merchant Alexander Fink shop@holex.org The price I paid including delivery was €15.80 EUR Note, if you're not fluent in german, try: translate.google.co.uk Just paste the above links in and translate from German to English. |
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2004 LWB 2.5 AXD 130hp, K&N Filter, Allard EGR Pipe and Oil Breather Tank....
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Liquidfreak
Yardie
Joined: 25 Feb 08 Location: Cornwall Status: Offline Points: 839 |
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Posted: 17 Oct 11 at 10:02 |
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Many thanks fella.
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2004 VW T5 Panel Van T30 2.5 130 AXD Engine
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Kitawagon wrote: