Turbocharger Engine Failure 1.9 TDI 105 PS Touran

teileklaus wrote:

Hello, unfortunately, my touring engine failed at 153,000 km while I was overtaking in a sharp left-hand curve, with a loud "thump/hiss." It only responded poorly to acceleration. After stopping, the engine still ran almost silently at idle, and then I heard a whining noise that increased with higher RPM and decreased when slowing down. At first, I thought it might be a burst refrigerant line or the air conditioning compressor, but ultimately, I suspect it's the turbo. After driving for 1000 to 1500 meters, I pulled over to a parking area to check something again. The performance continued to decrease until it finally stopped. Keine Ölrauchwolke im Auspuff. Ölstand auf Minimum, Wasser voll, keine MIL Lampe. Aprovided. Being short on time (working the night shift), I had someone pick me up there. I'll go get him tomorrow. Who has contact information for BKC Motors? What's the actual value of this thing? Oh, the timing belt and water pump were replaced at 125,000 km. with a forced greeting, Klaus

Hi,

My condolences.

In Langgöns, near Gießen, there's a recycling center (Andrew Strunk) where I've always been able to find what I'm looking for.
My AXR probably won't be of any use to you...

I submitted a suspicion report, thanks for the tip, Bertil.
I actually thought that the turbo was leaking oil and producing smoke, and that the engine would then rev up without being given any throttle.
That's why I'm still unsure about what's really going on.

Hello, so the turbocharger is out, and the impeller shaft is broken.
That was a tough job. Specifically, the upper 12mm nuts on the manifold, which is part of the loader, are difficult to access and are only reachable in some cases with a 1/4-inch socket and a short extension, but a 1/2-inch combination wrench is needed for the high loosening torque (due to rust), and that doesn't fit on every nut. Also, the exhaust pipe of the auxiliary heater was in the way and had to be removed. On vehicles with an additional DPF, the front axle needs to be lowered partially to create enough space.
Unfortunately, I couldn't loosen the oil supply line to the turbocharger located at the top, between the variable turbine geometry (VTG) and the housing. The union nut turned along with the line and the short threaded piece screwed into the turbo, so I had to bend the line. The new turbocharger comes with a mounting kit and new lines.
So, I'm now hoping that the engine is undamaged, and that the hissing/whistling sound from the faulty turbocharger may have also come through the EGR system, because the broken piston was restricting the exhaust more than usual.
A KKK turbocharger was installed, and it will be replaced with a BTS turbocharger and adapter kit.

Hi.

Does your engine also have that unusual charge air duct running underneath it, like the BRU model? I mean, the turbocharger is located on the right side, underneath the engine, and the duct runs forward from there.
LLK
and then from the left, across in front of the engine, to get back to the upper right.

What do you mean by "BNZ" in your signature? Is that a 2.5 TDI engine in a T5?

Ah, reading BKC... has he already connected the LLK output at the top right?


What I had to take out to only replace the first pressure pipe .

Interestingly, the turbocharger on this specific vehicle had already failed twice (in 260,000 km).

m;

Oh, that's an error with BNZ. I'll correct it right away.
And no, the LLK (low-level current) connectors are located on the bottom right and left, and I've also checked all the LLK hoses; that would have definitely shown an error.
It's interesting that the charger is relatively small, with a diameter of probably only 30 mm on the pressure side, before opening into a large rubber hose. In my opinion, this is terrible from a flow perspective. Only the 1.6 Ford Focus had a smaller charger.
Okay, I've left the damaged oil pipe in place for now, so I can properly position everything between the hoses and pipes on the left side, underneath the tandem pump, all the way to the oil filter. The oil pressure sensor also needs to be removed to access the nut. Everything is very tightly packed and difficult to access.

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

What is a 'BTS with a grow kit in exchange' offer?

Okay, so it's a replacement charger, a new one to replace the old one, and you also get the oil lines and seals as a repair kit.
Alternatively, you could opt for a cheaper loader and then source the more expensive individual parts from a VW specialist.

What is 'BTS' in this case?

It sounds suspiciously like cheap garbage again.
Why not offer an original KKK instead?

All parts suppliers offer BTS, BU, or other brands. What I'm hearing from VW is that the quality of their chargers isn't much better, as they tend to fail regularly between 30,000 and 150,000 kilometers.
He wanted to offer a dealer discount of just 7% on something costing over 1300 euros, despite being a "premium workshop" and all, plus the additional necessary pipes, seals, etc.
Unfortunately, I first had a clutch problem with my motorcycle, and I'm currently rebuilding the crankshaft of my Agria 2600 RL. I'm being careful with my money, and it's not just a few hundred euros more when going to a professional mechanic.

Sorry, you are stupid.

You can purchase an original KKK component as an accessory.
You don't have to do that at VW @ Apotheke.

And then it won't cost more than any random piece of junk that has 'BTS' on it.
The topic comes up so often in this forum; people should have learned about it by now. Especially those who are familiar with the subject should know better.

When it comes to their own vehicles, they don't use cheap materials, but rather strive to use standard materials.

But go ahead, it's your car.

Quote:

if they regularly fail between 30,000 and 150,000 km.

Definitely not normal, but nonsense.

"That's what I heard today from a VW master mechanic."
"That's nothing unusual; they've installed many of them before."

mullemaus wrote:

Sorry, you are stupid. You can purchase an original KKK component as an accessory.

Ah, I ordered from Bosch/Trost today, not from eBay.
On the other hand, I can still go back; he's not here with me yet.
Okay, then suggest some better sources where I can find it at reasonable prices. It's not like it cost 397 euros instead of 1260 euros.

The BKC engine has the same pipe on the turbocharger as the BRU engine: 1T0 145 790 B.

There is a silencer box installed that is supposed to absorb the noise from the airflow. That's why the turbine side is so bulky.

"LLK connectors both at the bottom" means it has that strange piping arrangement like the BRU. Both turbo connectors go to the right.

Should be a BV39A: http://www.piesedindezmembrari.ro/imagini/75561188-70807311-72437055.jpg

m;

Okay, both turbo hoses go to the right.

Sorry, you are stupid.

You can purchase an original KKK component as an accessory.


Ah, I ordered from Bosch/Trost today, and not from ****.
On the other hand, I can still go back; he's not here with me yet.
So, please suggest better sources with reasonable prices. It's not like it cost 397.- instead of 1260.-.

What does 'Bosch/Trost' have to do with the part itself?
Buying from places like eBay has nothing to do with it. It's simply about not buying cheap junk, but instead installing a proper part in your own car.

400€ for a replica/repaired item, versus 699€ for a new and original one.

http://www.ebay.de/itm/Turbocharger-including-gasket-set-Audi-A3-1.9-TDI-BorgWarner-NEW-Turbo-BKC-BLS-BXE-/251314009792?pt=DE_Autoteile&hash=item3a837b76c0

What do you buy for your own personal car? And according to some sources, it can even be more affordable.