Motorschaden (Turbolader) 1,9 TDi 105 PS, Touran 2005 | Posts 16+

Quote:

A KKK turbocharger was installed, and a BTS turbocharger with mounting kit is being installed in its place.

It's not uncommon for the shaft to break on KKK turbochargers. I've experienced this twice myself (once with a 3C engine with a BLS turbo, and once with a G5 engine with a BKC turbo), where the compressor wheel shattered afterward, and the engine stalled due to lack of air .

Oh, so the quality isn't the best? Well, when you're talking about a price of 150,000, you can expect some compromises. Fortunately, the manufacturer still covers it under the warranty for the first 30,000 km.
edit:
Okay, so I've been searching online for KKK/Borg Warner turbochargers, and I found one for €699, including seals, as suggested. I also just found a new one for €607.
http://www.ebay.de/itm/Turbocharger-Altea-XL-1P1-1-9-TDI-74-kW-105-PS-Engine-BXF-BXE-038253056LX-NEW-/330981998954?pt=DE_Autoteile&hash=item4d1010816a
In addition to that, there's the oil line and the seals. Thank you for the help, on the horse.

vwSchrauber wrote:

Quote: A KKK turbocharger was installed; in exchange, a BTS turbocharger with an adapter kit is being fitted. It's not uncommon for the shaft to break on KKK turbochargers. I've experienced this twice myself (once with a 3C engine with a BLS turbo, and once with a G5 engine with a BKC turbo), where the compressor wheel shattered afterward, and the engine stalled due to lack of air

.



"If you no longer want the KKK turbocharger, you can install the Garrett 7518515004S, which should be a direct replacement. The price is in the same range."

for example, also here: http://www.ebay.de/itm/Turbolader-VW-Passat-1-9-TDI-77-kW-105-PS-Motor-BKC-BXE-Garrett-751851-5003S-/231026728954?pt=DE_Autoteile&hash=item35ca441ffa

Mpire.

"Stay away from items like that sold on online marketplaces; the chances of them being what they're advertised as are slim."
I've had so many bad experiences with products from that online marketplace that I don't buy anything there anymore.
The best example is a timing belt kit from Contitech with INA pulleys. After 25,000 km, the pulley failed, and I only managed to avoid a timing belt rupture by chance.

The new parts from my supplier showed that Ina had embossed its logo, while the eBay parts had it printed on.
Please send me your key number via private message.
Best regards,

Quote:

If someone doesn't want a KKK anymore, they can install the Garrett 7518515004S, which should be a 1:1 replacement. The price is in the same range.

Okay, that's correct for a Touran BKC, I've done it before. Unfortunately, it doesn't work with the BLS in the 3C - the charger is installed in a mirror-image configuration, and only a KKK is available.

Quote:

exactly reversed

I would attribute the use of the word "wrong" more to the BKC.
How often the air has to go around the corner...
And those crazy pipes that swirl around the dipstick...

But I know what you mean.

m;

Okay, the new LLK (likely referring to a liquid-cooled oil cooler) has arrived, and the new turbocharger kit, including the gasket set and oil feed line, has been ordered.
I got the Viton seals from VW, and now I'm also replacing the A/C condenser with a new dryer. Since everything is already disassembled, I might as well do it. The lower part of the condenser is completely clogged with dirt and debris, and the fins are bent due to stone impact, so hopefully I can restore the airflow to a like-new level. I'll have it filled with refrigerant once everything is put back together.

teileklaus wrote:

Okay, the LLK (likely referring to a specific part) is here, and the new Turbopaket with the gasket set and oil line has been ordered. I got the Viton seals from VW, and now I'm also replacing the A/C condenser with a new dryer. Since everything is already disassembled, it makes sense to do it. The lower part is completely clogged with dirt and debris, and the fins are bent due to stone impacts, so hopefully I can restore the airflow to a like-new level. I'll have it filled with refrigerant once I have everything assembled.

When replacing the dryer filter, please install it immediately after opening the package and removing the protective caps. If you leave the dryer filter exposed without a protective cap, it will become saturated with moisture within approximately 4 hours and will no longer be usable.

Sure, thanks Master, that's how I intended to do it.
So, the KSM package included a new Garrett turbocharger with all the accessories.
Despite that, I ordered a brand new charger (KKK or Garrett) from a different supplier at a much lower price. The LLK (low-pressure coolant pump) has also arrived, along with the green LL seals from VW. The air conditioning condenser and dryer are arriving tomorrow. I hope the old seals are in good condition, but if not, I'll either try to get new ones or contact VW again to see if they can be purchased individually.
"On my daughter's Polo, it was leaking exactly at the dryer seal. I removed the old sealant, cleaned the Viton O-rings, lubricated them with a little oil, and installed the new dryer cartridge. It immediately sealed and held below 15 bar of nitrogen pressure."

Okay, so the loader is installed, and both AT loader packages contained new loaders.
The chargers are only being collected to be scrapped.
Therefore, I find "you are stupid" a bit harsh, Mullemaus, especially when we're not sure if BTS-rebuilt scrapers are being used. Even with BTS via KSM/Trost, new Garrett chargers are being shipped! Now I'm sure. I also gladly accepted the tip not to use rebuilt chargers. However, I found the tone a bit too blunt.
I filled the oil feed line to the turbo with 50 cc of oil, then let it run for a few minutes at idle to ensure proper oil pressure and to bleed any air from the turbocharger. I also replaced all the Viton seals on the air intake pipes, as well as the intercooler and the A/C condenser.
Before the high-pressure temperature sensor, I had a problem with a part that occasionally showed up in the error memory; it's supposed to cost almost 60€ from VW, and it was in stock.
However, it can also be replaced without losing pressure, even after the refrigerant has been replenished, because a valve is installed underneath it.
"Tomorrow I'll assemble the front end, and then everything should be working properly again. The boost pressure follows the target value well, up to 1400 mbar at idle, without any load. I'll do another test drive tomorrow."
Thank you for all the tips.
The filter dryer was already screwed into the condenser fitting, and this fitting was closed with two plastic caps, but it still needs to be evacuated.
I have, as instructed , kept the open hours as small as possible.
Best regards, Klaus.

So, the loader is installed, and both AT loader packages contained new loaders.
The chargers are only being collected to be scrapped.
Therefore, I find 'you are stupid' a bit excessive, Mullemaus, especially when one is not certain that scrap loaders modified by BTS are being used. Even with BTS via KSM/Trost, new loaders from Garrett are being shipped!


Then, choose to express .

'Exchange loaders' just sound like cheap, low-quality products. Everything else is simply a 'new loader for exchange.'
Ultimately, it doesn't matter who you buy it from.


Here, it seems like there are new ones now, so everything is good.

I didn't know what was in the package beforehand, but I assumed everything would be handled well, with good warranty processing in case of any issues. I suspect that Trost KSM can't afford to use cheap parts in the long run. Even with VW, the part number includes "AT," even though they use new parts. Now, it's time for the final test drive and to have the air conditioning system refilled.
Let's see what the boost pressure does. Yesterday, it was a bit hesitant, always a little below the target value.
Best regards, Klaus.

Quote:

The top part is still a bit thick, like before.

Also, also auch check the air mass and differential pressure to see if they are "normal."

If the DPF has ingested a lot of oil due to the faulty turbocharger, it certainly won't become more permeable.

[Translating...]

BKC == noDPF

Okay, Rainer, I'll check the air mass. Luckily, I don't have a DPF.
So, and also no differential pressure.
I have a very high AGR (Abgasrückführung) mixing ratio, with the control system exceeding 85% of the maximum value at full load. Is this open or closed? At low load, it's closer to 25%.

At full load, there is no regulation of the air mass, and the EGR is too.

In this case, we are only interested in the actual value, checking whether it is acceptable compared to other vehicles, and verifying that the limit related to air mass is not being exceeded in measurement block 8.