AAZ Turbo Removal

[Andyvandy]

Hi,

In advanced state of despair after having to replace the exhaust pipe on the van and finding the securing nuts and studs on the turbo totally rotten with rust.
Any attempt to remove them will almost certainly result in the studs shearing off in the turbo.
Given its position I cannot easily drill them out in situ so will need to remove the turbo. I plan to cut off the exhaust pipe angle grinder style before attempting removal.

So here is the 10 zillion dollar question - is it possible to remove the turbo without having to remove the engine?
Looking at its location it seems incredibly difficult to do.

Any helpful suggestions very gratefully received.

I shall now go and sob into my glass of beer.....

Thanks

Andy - on a rare warm day in north east Scotland.

[lloydy]

You should have to remove the whole engine, just the exhaust manifold. You could then do it on a bench.

[HarryMann]

If you are going to remove the 4 12 point (13mm bi-hex socket)... set screws that hold turbo to manifold...
Then it is sometimes possible. .
A 3/8" set with a small powerbar
Wire brush the thread protrusions thoroughly and soak top and bottom in plusgas or rust buster for a day or two. Heat should help but i managed without. I maybe gave them a fairly hefty thwack with a bluff angled chisel... it's in the Wiki under Tools Tips & Techniques - Bolt nut removal


There is one difficult to get onto... use a new or good 13mm bihex socket. Keep straight onto it. They'll creak and squeak and come out in jumps and jerks probably.
Work slowly and if they loosen keep backing off and re-soaking.
The bolts are £13 each from VW or BY i think.
I replaced two.
There are two long and two short.
Not a problem if one breaks... it will then wind out of turbo fairly easily once you get it moving with a drift.

You may have to move/remove some stuff to get straight on them such as the turbo oil feed line.
Original torque is only about 45 N-m i believe.