Problem with VTG cleaning

Okay, here's the quick story. A friend's ASZ Sharan had lost power. After a brief check, it was clear that the boost pressure adjustment was completely off. The VTG rod was completely stuck and wouldn't budge, even with force (I tried everything, from a small syringe to a huge syringe).
He happened to find a new turbocharger available at an online auction site. After I disassembled it and cleaned the VTG (variable transmission gear) in that area, it worked perfectly and there was no noticeable play.
Now I have the original one here, and it's causing me concern. After disassembling and taking it apart, this is what I found:

www.matthiasmann.com/Bilder/DSC00160.JPG
www.matthiasmann.com/Bilder/DSC00161.JPG


I can only say that the one from egedöns looked much better. Well, you're always happy to get your hands dirty, and that's how I started. None of the guide vanes on the adjuster could be moved. Not even a little bit. I then soaked them overnight in diesel and cleaned them the next day with a toothbrush. It looks great, except that all the guide vanes, except for one, can now be moved easily. I then carefully tried to move it with pliers (gripping the back of the adjuster). No chance. Does anyone have any ideas? I was already thinking about a heat treatment, but would that make sense? I don't want to break anything, because even if it's broken, it can still be used as a spare part once it's fixed.

Currently, it looks like this:

www.matthiasmann.com/Bilder/DSC00167.JPG

I am grateful for any advice!

Hello,
clear case for a thorough ultrasonic cleaning bath;-)

Best regards, Robert.

matthiasTDI96 wrote:

Except for one guide, all of them can be moved very easily. I then carefully tried to move it with pliers (attached to the adjustment mechanism at the back). No chance. Does anyone have any ideas? What means can be used to address that?

Hi Matthias,

If there's no risk of breakage (e.g., due to the material of the shovel), I would try to gently tap the stuck shovel back and forth in the axial direction with a very small hammer, in an attempt to "break" the blockage.
Try turning it repeatedly and use a rust remover to help.

A controlled heat treatment can be helpful, as the VTG (vacuum turbine generator) must be heat-resistant up to approximately 700°C.

Okay, I was also planning to check that specific part. You can't adjust the guide vanes, so I think there's a break there. It might be possible to adjust the rear part of the mechanism. But somehow, I'm still not quite ready.
Ultrasonic cleaner... hmm, hadn't even thought about that. Maybe I'll bring it in tomorrow and put it in the ultrasonic cleaner in the electroplating area. Do you think it will make a difference? It appears that the wave is completely stuck, and you can see through the gaps between the contact surfaces.
I've also tried using rust remover. In fact, I've practically emptied the entire gun cabinet... and there's been no improvement. I haven't worked with mechanical systems before either.

For Ulf Database, if you're still collecting:

3K Loader.
K39b 0005

VW Part Number 038 253 019H.

Exhaust turbine diameter, unsurprisingly, 39mm.
The inlet diameter of the compressor is 36.8mm, and it narrows down to approximately 33mm, as far as can be measured up to the compressor impeller.

I just pulled that thing out of the diesel bath again, and look... diesel doesn't just provide heat and help things move. Everything is working again. After a lot of back and forth, they are finally soft and pliable again.

But there's something else. This defect probably occurs more often. Is it possible to purchase the part shown in the photos separately? The 3k-warner website doesn't yield any results, and turbodriven.com seems to be down today.

Sure, here's the translation:

"Anyone have any sources?" Maybe this will help someone.

Hello Matthias!

What kind of deposits were those? Was the TDI engine fueled with US-spec diesel? It looks like sulfur deposits, that's incredible!!!
As you may know, I recently experienced similar problems with the VTG (Variable Turbine Geometry) on my GT1749V turbocharger. The adjustment mechanism was so stiff that it was almost impossible to make any adjustments without assistance and brute force. Meanwhile, the VTG is moving again due to negative pressure .

One more question, just out of curiosity: Was the donor vehicle a standard model or a tuned one?

Regards,
Alex.

Oops... I just realized you were waiting for a response.

I can't tell you for sure, but he always believed it was running on diesel. However, the VTG was definitely switched to the "off" position when he arrived with the tractor, and he was puffing out smoke like a bonfire. He claimed to have been driving like that for a while. What made me suspicious about the deposits was all the white stuff. I also checked for coolant leaks, but found nothing. The thing ran great after the repair, and it hasn't resurfaced to this day.
The vehicle is not tuned.

The VTG only became operational after a long period of troubleshooting and ultimately, force. After that, everything went smoothly. Absolutely convincing, as I found.

matthiasTDI96 wrote:

However, the VTG was stubbornly stuck in the "closed" position when the tractor arrived, and it was emitting a thick cloud of smoke.

So, a fog machine just because the VTG is constantly closed (resulting in maximum pressure buildup)? What color was the smoke?

As black as night... so, not exactly disco-friendly.

Then, does "geschlossen" refer to a minimal pressure buildup, or what?

Herr Antje wrote:

So, does "geschlossen" mean a minimal pressure buildup is intended, or?

Incorrect: /viewtopic.php?t=10810

Question to the group:
How can a TDI engine produce black smoke (unburned diesel) due to a faulty VTG (Variable Turbine Geometry)? Does the back pressure from the exhaust push against the EGR valve?
That would mean that the load (LD) is lower, so exhaust gases flow through the open EGR valve into the intake side and displace fresh air there.
Accordingly, the LMM signal should drop to the basement -> the turbidity takes effect and prevents excessive soot formation.

Somehow, it's puzzling...

ulf wrote:

Herr Antje wrote: So, does "geschlossen" mean a minimal pressure build-up, or? Incorrect: /viewtopic.php?t=10810 Somehow mysterious.

Therefore, I thought that matthiasTDI96 might have accidentally mixed up the terms, because it also seemed puzzling to me... However, since he's a professional, he probably knows what he wrote. So, there must actually be an explanation for it. I would also be curious to know that.

Okay... this has to do with the fact that I'm not expressing myself clearly: then be direct and open. When I said "zu," I meant minimal pressure buildup. And there isn't a meaningful explanation for this "Vestbrennposition" either. I need to find a picture that clearly shows what I'm talking about... that way we won't misunderstand each other, because I might have understood something differently. Sorry.

matthiasTDI96 wrote:

By "with," I meant: minimal pressure buildup.

Okay, the "correct" terms aren't widely known yet... in older posts, I had written it the other way around.

"However, I believe that a TDI engine with a variable geometry turbocharger (VTG) should not normally produce excessive soot, even if the VTG is constantly in a fixed position. This would only happen if the engine is poorly tuned or if the exhaust gas recirculation (EGR) system is stuck open."

Yes, the EGR valve should have been closed, as I didn't change anything, and it was working later. I can't rule out a chip issue, as I don't know the driver well enough. What all sorts of things people do in their free time...
"It made a noise when accelerating. I only drove it for 200 meters, and that's when I knew which direction I needed to look for the problem. However, the owner seems to have driven it like this for a while, because my colleague had already asked me about two weeks before I even saw the car what could be done if there were any problems. As mentioned before, the problem was that the flaps were stuck so tightly that vacuum wouldn't have been able to fix it. And please look at the photos again." So, my turbocharger didn't look anything like that after approximately 60,000 km.