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Author Topic: turbo removal  (Read 8264 times)

Offline redwon

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  • Model: Galaxy Mk2
  • Spec: 02 1.9 TDI
turbo removal
« on: November 11, 2012, 05:05:27 PM »
Hi There
I read Chrispb's thread on turbo tremoval. my daughters galaxy is the AUY engine. I had a look in the haynes manual and in the turbo removal section, it states to remove the engine mounting and drag the engine forward supported on a trolley jack. Do I really need to do this? I am a bit confused? ???
Please don't get me wrong, I know you guys have had loads of experience, I am just trying to plan my route of attack to get the turbo off as easy as possible.
Thanks
Dave

Offline Chrispb

  • Mindsaysyesbodysaysnono
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  • Model: Galaxy Mk2 Auto
  • Spec: 52reg TDI 115 Ghia
  • First Name: Chris
  • Region: South East
  • Country: United Kingdom
Re: turbo removal
« Reply #1 on: November 11, 2012, 05:54:01 PM »
Haynes and TIS both suggest moving the engine forward.
Problem being this puts strain on the fragile aircon pipes also the car will be on ramps or stands, with a jack in the middle supporting the engine you will really restrict yourself for space so I opted for removing the o/s driveshaft instead, plus the fact my driveway is on a slope so balancing engine on a jack is a dodgy option.
2009 Kia Sedona GS In Black 2.9CRDI 183PS. 5 Speed Manual WAV.
2003 MK2 Galaxy Ghia In Solid Black 1.9 TDI 115PS. 5 Speed Automatic.

Upgraded Eberspächer booster heater  to independent heating with 7 day timer.

With VCDS lite (full version) need a code clearing or want to scan for faults in the north kent area, PM me.
All for a pint of Strongbow.

The FordMPV.com Forum - The free forum for questions and answers relating to the Ford Galaxy, S-Max and C-Max

Offline redwon

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  • Posts: 32
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  • Model: Galaxy Mk2
  • Spec: 02 1.9 TDI
Re: turbo removal
« Reply #2 on: November 11, 2012, 08:07:52 PM »
OK Thanks. So I need to go through the procedure in the haynes manual of loosening hub bolt, anti roll bar link rod, carrier etc and then the dropping it down?

Offline Chrispb

  • Mindsaysyesbodysaysnono
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  • Thanked: 91
  • Model: Galaxy Mk2 Auto
  • Spec: 52reg TDI 115 Ghia
  • First Name: Chris
  • Region: South East
  • Country: United Kingdom
Re: turbo removal
« Reply #3 on: November 11, 2012, 09:42:51 PM »
The right hand drive shaft is removed complete with support bearing, you don't need to touch the lower ball joint or drop link.
Slacken hub bolt while on ground, then when on stands remove support bearing bolts, turn steering on full right lock unscrew hub bolt a few turns now tap the bolt until driveshaft/cv joint is released from hub, finally remove bolt completely you should now be able to withdraw the whole shaft.
You may need assistance as it's quite heavy.

Best to replace the hub bolt when refitting.
2009 Kia Sedona GS In Black 2.9CRDI 183PS. 5 Speed Manual WAV.
2003 MK2 Galaxy Ghia In Solid Black 1.9 TDI 115PS. 5 Speed Automatic.

Upgraded Eberspächer booster heater  to independent heating with 7 day timer.

With VCDS lite (full version) need a code clearing or want to scan for faults in the north kent area, PM me.
All for a pint of Strongbow.

The FordMPV.com Forum - The free forum for questions and answers relating to the Ford Galaxy, S-Max and C-Max

Offline redwon

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  • Posts: 32
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  • Model: Galaxy Mk2
  • Spec: 02 1.9 TDI
Re: turbo removal
« Reply #4 on: November 12, 2012, 10:03:34 AM »
 Thanks for that. [THANX]

Offline redwon

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  • Posts: 32
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  • Model: Galaxy Mk2
  • Spec: 02 1.9 TDI
Re: turbo removal
« Reply #5 on: November 12, 2012, 08:10:09 PM »
Ok, I have removed the bearing carrier and slackened the hub bolt, I have tried hitting the bolt to release the shaft from the hub but it wont move. I have not hit too hard as I am a bit tentative not to overdo it. Can these shafts be tight and stuborn to remove from the hub? ???
Thanks
Dave

Offline Chrispb

  • Mindsaysyesbodysaysnono
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  • Posts: 2979
  • Thanked: 91
  • Model: Galaxy Mk2 Auto
  • Spec: 52reg TDI 115 Ghia
  • First Name: Chris
  • Region: South East
  • Country: United Kingdom
Re: turbo removal
« Reply #6 on: November 13, 2012, 12:22:58 AM »
Have you got on a full right hand lock? you wont have enough clearance otherwise.
The shaft doesn't fit very far into the hub and normally just needs a few blows with a club hammer to release.
2009 Kia Sedona GS In Black 2.9CRDI 183PS. 5 Speed Manual WAV.
2003 MK2 Galaxy Ghia In Solid Black 1.9 TDI 115PS. 5 Speed Automatic.

Upgraded Eberspächer booster heater  to independent heating with 7 day timer.

With VCDS lite (full version) need a code clearing or want to scan for faults in the north kent area, PM me.
All for a pint of Strongbow.

The FordMPV.com Forum - The free forum for questions and answers relating to the Ford Galaxy, S-Max and C-Max

Offline Mirez

  • Pondering the next mod...
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  • Posts: 3570
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  • Model: Galaxy Mk2
  • Spec: 03 115PS Ghia
  • First Name: Mark
  • Region: South West
  • Country: United Kingdom
Re: turbo removal
« Reply #7 on: November 13, 2012, 12:08:16 PM »
They can be a little stubborn but should give with some solid whacks - Make sure though that once you've slackened the hub bolt, you do it back hand tight and then undo just half a turn or so. You want as much thread to be "in" as possible yet still allow it to move when hit.

I've never done it attached though, I always undo the 6 spline bolts on the other end of the shaft and allow it to drop clear (suspended with string) so its got plenty of room to move when it becomes free.
03 Ford Galaxy 1.9 TDI 115 Ghia in Spruce Green Metallic
With cream leather interior, Full Bodykit, Remapped at 145bhp, Lowered on 18's
06 VW EOS 2.0 T-FSI 210 Sport in Deep Black Pearl
With red leather interior with full Caractere bodykit, Remapped at 255bhp and sitting on 19's
14 VW Tiguan 2.0 TDI 177 R-Line in Deep Black Pearl
With black leather interior, panoramic sunroof and bi-xenon headlights.
08 Ford Transit 2.2 TDI 115 in Frozen White
With retrofitted everything except another slidey door! :)

VCDS HEX/CAN - Scans/Coding done in Wiltshire in exchange for winegums! :)

Offline redwon

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  • Posts: 32
  • Thanked: 0
  • Model: Galaxy Mk2
  • Spec: 02 1.9 TDI
Re: turbo removal
« Reply #8 on: November 13, 2012, 12:44:04 PM »
Ok I will try again tonight, I can see what chrispb is on about now with the clearance. When the carrier is removed from the engine block, and (eventually) ::) the shaft is removed, it opens a big hole for the turbo to drop out. I will keep you posted on progress.
Thanks again. I will probably be posting for further help when I get the turbo out!! ;D

Offline Mirez

  • Pondering the next mod...
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  • Posts: 3570
  • Thanked: 130
  • Model: Galaxy Mk2
  • Spec: 03 115PS Ghia
  • First Name: Mark
  • Region: South West
  • Country: United Kingdom
Re: turbo removal
« Reply #9 on: November 13, 2012, 05:19:11 PM »
Can you take some photos when you're under their - the more we can build up the reference library the better ;)
03 Ford Galaxy 1.9 TDI 115 Ghia in Spruce Green Metallic
With cream leather interior, Full Bodykit, Remapped at 145bhp, Lowered on 18's
06 VW EOS 2.0 T-FSI 210 Sport in Deep Black Pearl
With red leather interior with full Caractere bodykit, Remapped at 255bhp and sitting on 19's
14 VW Tiguan 2.0 TDI 177 R-Line in Deep Black Pearl
With black leather interior, panoramic sunroof and bi-xenon headlights.
08 Ford Transit 2.2 TDI 115 in Frozen White
With retrofitted everything except another slidey door! :)

VCDS HEX/CAN - Scans/Coding done in Wiltshire in exchange for winegums! :)

Offline redwon

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  • Posts: 32
  • Thanked: 0
  • Model: Galaxy Mk2
  • Spec: 02 1.9 TDI
Re: turbo removal
« Reply #10 on: November 13, 2012, 09:22:16 PM »
Hi Mirez. I will take some pics tomorrow evening. I managed to get the drive shaft out, it was quite a tight fit and it is a tight fit getting the shaft away from the hub, but it is doable as chrispb explained.
I started taking off the intercooler pipes as I was making good progress, 8)
Did I mention that this is the first Turbo charger I have worked on? As I removed the lower intercooler pipe, a deluge of oil cascaded onto my arm, shoulder and tool box :-[
So I spent the rest of the evening cleaning up :'(
Any way, showered and all tidied up ready for a go tomorrow evening.  8)
Do I need to clean out the intercooler? as there was oil in both pipes.
Please be patient if these questions are a bit mundane to you guys, I am trying here.
I am going to attempt to remove the intake manifold tomorrow evening, just off to read from the reference library cheers

Offline Mirez

  • Pondering the next mod...
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  • Posts: 3570
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  • Model: Galaxy Mk2
  • Spec: 03 115PS Ghia
  • First Name: Mark
  • Region: South West
  • Country: United Kingdom
Re: turbo removal
« Reply #11 on: November 13, 2012, 10:40:09 PM »
Cheers, they'll be helpfull!

NEVER worry about asking any question on here, at some point we've all asked them!  The oil is, in this case, a good sign as it means the turbo has indeed failed (there should only be a very small amount in there)

You should get as much oil out as possible so yes, drain the intercooler. Haynes will tell you to drain the coolant and various other things but on the 115 you can drill four holes from the front into the cowell to acces the bolts without taking anything else apart.

Good luck and well done on the work so far!!
03 Ford Galaxy 1.9 TDI 115 Ghia in Spruce Green Metallic
With cream leather interior, Full Bodykit, Remapped at 145bhp, Lowered on 18's
06 VW EOS 2.0 T-FSI 210 Sport in Deep Black Pearl
With red leather interior with full Caractere bodykit, Remapped at 255bhp and sitting on 19's
14 VW Tiguan 2.0 TDI 177 R-Line in Deep Black Pearl
With black leather interior, panoramic sunroof and bi-xenon headlights.
08 Ford Transit 2.2 TDI 115 in Frozen White
With retrofitted everything except another slidey door! :)

VCDS HEX/CAN - Scans/Coding done in Wiltshire in exchange for winegums! :)

Offline redwon

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  • Posts: 32
  • Thanked: 0
  • Model: Galaxy Mk2
  • Spec: 02 1.9 TDI
Re: turbo removal
« Reply #12 on: November 14, 2012, 09:31:14 PM »
I am trying to load pics, I have resized them in paint, but what info needs inserting between the image brackets?

Offline Chrispb

  • Mindsaysyesbodysaysnono
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  • Posts: 2979
  • Thanked: 91
  • Model: Galaxy Mk2 Auto
  • Spec: 52reg TDI 115 Ghia
  • First Name: Chris
  • Region: South East
  • Country: United Kingdom
Re: turbo removal
« Reply #13 on: November 14, 2012, 11:46:28 PM »
You can add pics by using the attach files button by clicking attachments and other options, pics reduced to 800X600 is about right
2009 Kia Sedona GS In Black 2.9CRDI 183PS. 5 Speed Manual WAV.
2003 MK2 Galaxy Ghia In Solid Black 1.9 TDI 115PS. 5 Speed Automatic.

Upgraded Eberspächer booster heater  to independent heating with 7 day timer.

With VCDS lite (full version) need a code clearing or want to scan for faults in the north kent area, PM me.
All for a pint of Strongbow.

The FordMPV.com Forum - The free forum for questions and answers relating to the Ford Galaxy, S-Max and C-Max

Offline redwon

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  • Posts: 32
  • Thanked: 0
  • Model: Galaxy Mk2
  • Spec: 02 1.9 TDI
Re: turbo removal
« Reply #14 on: November 16, 2012, 10:18:09 PM »
983-0
Hope the pics load up.

Offline redwon

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  • Model: Galaxy Mk2
  • Spec: 02 1.9 TDI
Re: turbo removal
« Reply #15 on: November 16, 2012, 10:21:37 PM »
The first pic is the complete shaft and carrier support off.
The second pic shows how much roo,m it leaves once the drive shaft is out.
Pic 3 shows how Crispb explanation of putting the full lock allows the shaft to come out
Look at the state of the EGR valve, How do I clean it?

Offline Chrispb

  • Mindsaysyesbodysaysnono
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  • Posts: 2979
  • Thanked: 91
  • Model: Galaxy Mk2 Auto
  • Spec: 52reg TDI 115 Ghia
  • First Name: Chris
  • Region: South East
  • Country: United Kingdom
Re: turbo removal
« Reply #16 on: November 17, 2012, 12:27:24 AM »
Hi Dave

Glad to see your making progress, the easiest available stuff for cleaning the EGR is carb cleaner spray and a small scraper or screwdriver.
By the way have seen them worse than that, once you have the inlet manifold off that will also need doing, be careful of the rubber ring around the EGR as it's not available separately.

Noticed those splines look dry of grease where the driveshaft enters the gearbox flange, be sure to grease this when refitting
2009 Kia Sedona GS In Black 2.9CRDI 183PS. 5 Speed Manual WAV.
2003 MK2 Galaxy Ghia In Solid Black 1.9 TDI 115PS. 5 Speed Automatic.

Upgraded Eberspächer booster heater  to independent heating with 7 day timer.

With VCDS lite (full version) need a code clearing or want to scan for faults in the north kent area, PM me.
All for a pint of Strongbow.

The FordMPV.com Forum - The free forum for questions and answers relating to the Ford Galaxy, S-Max and C-Max

Offline redwon

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  • Posts: 32
  • Thanked: 0
  • Model: Galaxy Mk2
  • Spec: 02 1.9 TDI
Re: turbo removal
« Reply #17 on: November 17, 2012, 11:25:33 AM »
Yes, getting there slowly. Fortunately my daughter is insured on my wife's golf so she can get the kids to school and my son in law has a van, so there is no mad panic to get the car back on the road.
There was no way she could afford to have the car repaired in a garage and she loves the Galaxy for its usefullness. I have been doing a couple of hours each evening, weather permitting. But its obviously taking me a bit longer as this is unknown territory.

 A couple of usefull items I found helpful. - A long series 6mm allen key to remove the bolts of the first part of the heat exchanger described in your PDF. You can access them from below. I also found a mirror helpful to locate the heat exchanger mounting bolts and the inlet manifold bolts.
I may have a go at dropping the turbo this afternoon (Saturday) I am a bit concerned at getting to the oil feed pipe, it looks awkward to get a spanner on. I have ground a 17mm spanner to your spec in the PDF cheers
Dave

Offline redwon

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  • Model: Galaxy Mk2
  • Spec: 02 1.9 TDI
Re: turbo removal
« Reply #18 on: November 18, 2012, 04:28:46 PM »
Ok, The turbo is off, the intercooler off (great tip about drilling the holes to get at the intercooler mounting bolts [agreed] )
I am replacing the oil feed pipe as this seems to be a part of the warranty with a lot of replacement turbo's
Couple of questions, Any ideas on how to clean the oil out of the intercooler?

 When replacing the oil feed pipe, I ned to prime the oil into it, How can I do this and still have access to the nut on top of the turbo? and not start up the engine.

I am going to start sourcing the parts, any reccommendations for turbo's Gaskets etc.
Thanks in advance
Dave

Offline Chrispb

  • Mindsaysyesbodysaysnono
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  • Posts: 2979
  • Thanked: 91
  • Model: Galaxy Mk2 Auto
  • Spec: 52reg TDI 115 Ghia
  • First Name: Chris
  • Region: South East
  • Country: United Kingdom
Re: turbo removal
« Reply #19 on: November 19, 2012, 04:38:49 AM »
Wash out intercooler with degreaser then leave on end to drain.

Take out fuse 14 to prevent engine starting.
2009 Kia Sedona GS In Black 2.9CRDI 183PS. 5 Speed Manual WAV.
2003 MK2 Galaxy Ghia In Solid Black 1.9 TDI 115PS. 5 Speed Automatic.

Upgraded Eberspächer booster heater  to independent heating with 7 day timer.

With VCDS lite (full version) need a code clearing or want to scan for faults in the north kent area, PM me.
All for a pint of Strongbow.

The FordMPV.com Forum - The free forum for questions and answers relating to the Ford Galaxy, S-Max and C-Max

Offline redwon

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  • Model: Galaxy Mk2
  • Spec: 02 1.9 TDI
Re: turbo removal
« Reply #20 on: November 21, 2012, 12:58:25 PM »
I called Fords about the oil feed pipe, £62.00, I called Volkswagon £36.00 :o And they were more helpful. I told them I had a galaxy but is was VW running gear and they were happy to oblige.
Just called a company called Turbo Dynamics who had been reccommended, and am now waiting on a Turbo.
Hope its dry this weekend. :-
I removed a coolant pipe to get at the oil feed pipe to remove it and also to change the coolant temp sensor, put a bucket underneath but some coolant went into the inspection hole in the top of gear case, where you can see the starter ring, is there a drain on the casing or have I got a problem :-[
Dave

Offline redwon

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  • Spec: 02 1.9 TDI
Re: turbo removal
« Reply #21 on: December 01, 2012, 06:11:08 PM »
Well folks, the Turbo went back on, I changed the oil feed pipe aswell. Upon draing the old oil out of the
sump, I found the drain plug to be loose. I tried tightening it up but it just spun. So I removed the sump and took it to work (I work in a CNC Machine shop :P)  drilled and tapped it out to a M16 X 1.5 thread instead of the standard M14 X1.5, made up a new sump bolt with a copper washer. Put it back on today with some silicone gasket seal. I took out fuse 14 as Chrisbpb mentioned and put some clear hose on the new oil feed pipe, instead of connecting to the Turbo. I put the hose in a jar and turned the engine over. It took a good few cranks to prime the pipe, but it came through eventually. ;D
Put the pipe back on the turbo and started her up. She runs fine 8) I will take her for a blast tomorrow when I have tightened up the new drive shaft bolt, and see how she runs.
Thanks for the help to Mirez and Chripb 8)
Dave

Offline Mirez

  • Pondering the next mod...
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  • Posts: 3570
  • Thanked: 130
  • Model: Galaxy Mk2
  • Spec: 03 115PS Ghia
  • First Name: Mark
  • Region: South West
  • Country: United Kingdom
Re: turbo removal
« Reply #22 on: December 03, 2012, 10:46:58 AM »
Great news! How much was the total fix then?
03 Ford Galaxy 1.9 TDI 115 Ghia in Spruce Green Metallic
With cream leather interior, Full Bodykit, Remapped at 145bhp, Lowered on 18's
06 VW EOS 2.0 T-FSI 210 Sport in Deep Black Pearl
With red leather interior with full Caractere bodykit, Remapped at 255bhp and sitting on 19's
14 VW Tiguan 2.0 TDI 177 R-Line in Deep Black Pearl
With black leather interior, panoramic sunroof and bi-xenon headlights.
08 Ford Transit 2.2 TDI 115 in Frozen White
With retrofitted everything except another slidey door! :)

VCDS HEX/CAN - Scans/Coding done in Wiltshire in exchange for winegums! :)

Offline redwon

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  • Posts: 32
  • Thanked: 0
  • Model: Galaxy Mk2
  • Spec: 02 1.9 TDI
Re: turbo removal
« Reply #23 on: December 03, 2012, 07:36:54 PM »
I bought a new turbo from Turbo Dynamics £500.00 inc gasket set & Vat, The oil pipe from VW £36.00, oil, antifreeze, filter, inlet manifold gasket and a new coolant temp sensor £85.00 from GSW. So, I have spent about £620.00 to get this back on the road. Quite a lot to spend, but it would have been just scrap value as it was.
I took it out for a spin yesterday and it was OK. Still blowing out a bit of blue smoke on start up when cold. Once it is wamed up it is OK. I hope this clears.
Dave

 

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