Author Topic: BKD Turbo Removal  (Read 4016 times)

Offline Kalpesh

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BKD Turbo Removal
« on: May 30, 2014, 06:21:20 AM »
Hi all,

Looking for a guide to help if anyone has one or can point me in the right direction

Thanks

Kalpesh

Offline jason_rmh

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Re:
« Reply #1 on: May 30, 2014, 07:38:30 AM »

VCDS (Preston, Lancashire)

Offline kevster996

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Re: BKD Turbo Removal
« Reply #2 on: September 15, 2020, 11:29:16 PM »
Ive just done this on my 2005 GT TDI 140 4motion and its a bit of a pig of a job due to access. I did manage to pull the turbo out of the top of the engine but I split the turbo off the DPF/exhaust to make it easier (danger of doing this is that bits may drop down from insdie the turbo if you're not careful).

I had already removed the EGR cooler and EGR as it dumped about 4 litres of coolant in, in a few miles (luckily had 5 litres in the boot as it had been leaking on long journeys). Not having the cooler in the way was a big bonus, its clearly been changed once already.

My clamp on the exhaust side was stuck on so that took a while to get freed off as so little space to get tools in there, I got a few swings at it by using extensions bars and a hammer from above and plenty of wd40. I dropped the O/S drive shaft so I could undo the bolts (5 I think) holding the turbo to the exhaust side casing and also get to the oil pipe bolts on the turbo.

The bolt holding the DPF on was a pain to get to and tight - its a 13mm and you can undo from above by getting a ratchet on the underside - easier than undoing the 3 bolts on the block.

I ordered a new vacuum actuator as mine didnt feel very smooth and its one more thing to iron out the limp mode issue. The fuel temp sensor was coming up as a fault - seems intermittent but cheap to replace and tidied up and checked the wiring to it as it was a bit messy.

The turbo itself wasnt as bad as I thought it would be and the VNT flaps were free - it probably got a bit of a clean when 4 litres of water got dumped through the engine! The EGR was squeaky clean when that came off - again prob from the cooler failure.

Fingers crossed getting it all back on once Ive got a few new parts in. I hope this fixes the intermittent limp mode as Im running out of ideas!
Golf 5 2005, 2.0 TDI 4motion, remapped to 175bhp, lowered on eibach springs, GTI front end, GTI half leather interior

Offline Stupots

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Re: BKD Turbo Removal
« Reply #3 on: September 16, 2020, 04:11:57 PM »
@kevster996

Isn't yours a BKD engine too (same as mine) which doesn't have a DPF? Also, I had coolant dump issues on mine and it was a failed head/gasket. Early BKD engines are prone to porous heads, so I just replaced the engine all in one. Mine was blowing the coolant out of the expansion/top-up bottle, so may be a completely different issue.

I have to fit a turbo and change my clutch soon, so the less painless way (certainly on a 4motion) is taking the front off and having the engine out, but I know that's not an option for everyone (I just move the whole rad pack to one side, so no AC re-gas issues).

Good luck

Stu
« Last Edit: September 16, 2020, 04:29:36 PM by Stupots »
VW Golf Mk5 TDI Sport 4Motion

Offline kevster996

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Re: BKD Turbo Removal
« Reply #4 on: September 20, 2020, 11:28:15 AM »
Wow I guess engine out does make it so much easier - I struggled but got there in the end. When I put the turbo and manifold back in I did it from the bottom as not enough spce with them both bolted together and didnt fancy splitting the turbo again. Ok to get it in from below as long as the driveshaft is disconnected and also I took off the actuator as just not enough space with it on.

Now its all back together i still get limp mode which is REAL frustrating! At least I know my turbo is good and Ive replaced the actuator so one less thing to rule out. Engine def sounds different, wastegate noisier (I assume its that - after accelerating and changing gear I hear a louder sucky noise between changes). Im not sure how well Ive clamped up the exhaust turbo clamp as you cant see easily how well this goes back together. I blew a few intercooler hoses but this was because I didnt put the clips on properly.

To answer your question yes mine is a BKD engine but I have a receipt for a head change so I think thats all good. My expansion bottle was fine - no real leaks on the outside so it was the cooler. I was assuming it does have a DPF - big lump/box thats attached just after where the exhaust bolts to the turbo and then drops down past the lower bulkhead into a section with mesh on the outside?

Im going to take it to a local vw specialist and get them to read the codes as CEL is no right now. Its fine from cold but after a few mins the limp mode kicks in. If I stop and restart it clears.

All I can think of now is to change all vacuum pipes, swap out the vacuum solenoid block or possibly MAF?   

Its a fun car but its hacking me off right now as Ive spent way too much time underneath it!
« Last Edit: September 20, 2020, 11:35:06 AM by kevster996 »
Golf 5 2005, 2.0 TDI 4motion, remapped to 175bhp, lowered on eibach springs, GTI front end, GTI half leather interior

Offline kevster996

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Re: BKD Turbo Removal
« Reply #5 on: September 20, 2020, 11:36:51 AM »
@Stupots - how bad is your turbo? You could get away with a core replacement which is much cheaper than a whole turbo. Luckily mine looked ok and no end float or sideways float...
Golf 5 2005, 2.0 TDI 4motion, remapped to 175bhp, lowered on eibach springs, GTI front end, GTI half leather interior

Offline Stupots

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Re: BKD Turbo Removal
« Reply #6 on: September 20, 2020, 01:13:18 PM »
My turbo is fine, but has a hybrid going on  :laugh:
VW Golf Mk5 TDI Sport 4Motion