One hell of an oil leak!

Someone here recently removed and restored their 90PS turbo - they might be able to help?
 
Generally, apart from removal, the only job that the owner can do himself is clean the VNT mechanism but this one won't have one! Rebuilding is a job for the specialist.

RAB
 
Thanks guys.
I'm abit stuck with the oil feed pipe I just can't get a spanner in there with enough room to turn it. So I've decided to cut it off and replace.
The other issue I'm stuck with is the two bolts holding the turbo to the exhaust manifold have splined heads. The third is accessable from beneath and I have removed the 12mm nut.
I'm just off to have another look from underneath but at the moment I'll have to go and buy a splined socket to seperate manifold from turbo.

Don't worry I have no intention of refurbing it myself.
I'll let you know how I get on but my only thoughts so far are that it would have been more straightforward to remove the engine and do it all on the bench as I feel like a blind trainee gynecologist fumbling at the back of the engine!!!!

Cheers
Jonathan
 
Ok turbo now off. Although the oil pipe nut was slightly undone by my efforts the pipe was stuck in the union and destroyed the pipe. The two bolts through the exhaust manifold are 12 point and require the correct 12mm socket to fit.
I now understand why elsawin talks of removal from underneath. It is actually possible to attack the two bolts with the exhaust and inlet manifolds still on. The turbo then drops down but the driveshaft needs to be unattached from the engine end to create enough room for removal. Apart from the driveshaft removal that makes it only 7 bolts/nuts + the oil pipe.

Down to Audi today and have ordered all the bits I'm going to replace putting it back and the turbo has gone off to AET for refurb.

I haven't followed the oil pipe all the way back yet, I want to see what the new one looks like before dismantling any more and besides I want a day off.

Hopefully it will all go back on reasonably easily (ha ha)

Cheers

Jonathan
 
Apologies for the thread resurrection.

My project car (02 reg AMF) has a serious leak down the back of the engine that has resulted in an MOT failure and it seems to be the usual suspects. The pipe that runs around from the intercooler has always been pretty oily inside, and I'm reasonably certain that the oil is leaking out of the turbo due to it being knackered, then accumulating & leaking out of the wee drain holes in the EGR down the back of the block.

As part of the planned refurb, I've managed to accumulate so far a refurbished Garrett AMF turbo, turbo feed oil in and out pipes , an exhaust manifold with EGR pipe and an EGR as well as the various gaskets needed to link that lot together. However, I'm stuck on one significant issue because (for once rather than in spite of) the 7zap diagram.


Although this is a 3 cylinder engine, the diagram shows a 4-cylinder exhaust manifold and turbo, which have a different flange to the AMF one (trapezoidal rather than triangular). This means that the nuts and bolts are I assume not directly applicable. I think I've picked up that there are some 12-point spline-headed bolts (M8x46?) and possibly nuts as well, but I am really not sure about what fixings I should be getting to join the relevant bits together (presumably some or all may need replacing).

Does anyone have any better ideas or suggestions?
 
It's just a generic drawing. The part numbers should be correct though. The only items that need to be renewed are any nuts fastening the turbo/manifold/exhaust. You should use the special Audi/VW paste with the new nuts; taking things apart may explain why! If the nuts won't shift, use a nut splitter.

RAB
 
Apologies for the thread resurrection.

My project car (02 reg AMF) has a serious leak down the back of the engine that has resulted in an MOT failure and it seems to be the usual suspects. The pipe that runs around from the intercooler has always been pretty oily inside, and I'm reasonably certain that the oil is leaking out of the turbo due to it being knackered, then accumulating & leaking out of the wee drain holes in the EGR down the back of the block.

As part of the planned refurb, I've managed to accumulate so far a refurbished Garrett AMF turbo, turbo feed oil in and out pipes , an exhaust manifold with EGR pipe and an EGR as well as the various gaskets needed to link that lot together. However, I'm stuck on one significant issue because (for once rather than in spite of) the 7zap diagram.


Although this is a 3 cylinder engine, the diagram shows a 4-cylinder exhaust manifold and turbo, which have a different flange to the AMF one (trapezoidal rather than triangular). This means that the nuts and bolts are I assume not directly applicable. I think I've picked up that there are some 12-point spline-headed bolts (M8x46?) and possibly nuts as well, but I am really not sure about what fixings I should be getting to join the relevant bits together (presumably some or all may need replacing).

Does anyone have any better ideas or suggestions?

Hi @Robin_Cox - you planning on tackling this yourself? Sorry missed this thread first time around :)
 
Hi @Robin_Cox - you planning on tackling this yourself? Sorry missed this thread first time around :)

What I've learnt so far is 'don't tackle this yourself'! No chance on the mechanics - I'm simply not qualified, however I am usually pretty good at finding the parts at a decent price.

However. My usual EBay hunt resulted in variously some new parts from sites that seemed to be in the UK ordered, turning out to be the part for the LHD version, so not quite the right shape ; an oil pipe that was definitely for the LHD (wrong shape) sent in error ; an EGR that looked identical but was a mirror image of the correct part (anti-shudder valve actuator on opposite side) and would foul on the bulkhead if it could be fitted (single letter difference in the part number, missed the salient detail during the extended Ebay clickathon) ; a set of manifold gaskets that got put onto a pallet that Royal Mail misplaced ; a remanufactured turbo that started pissing oil out of both ends of the turbine when it was prefilled with oil (the supplier gave a full refund, no arguments) ; my own removed worn-out turbo then going off for refurbishing at a different and highly recommended place being delayed on arrival by a Covid scare, then rebuilt with all new parts and reinstalled last week and immediately starting to seep oil from between the casing halves on the test drive so that it is obvious it won't pass the MOT (oil leak from original turbo being the main fail on Sept. 1st) - and the supplier again is going to honour the warranty but the passage of time is just a bit frustrating as I don't like pissing off my mechanics .... the new turbo place did confirm however that the original turbo was properly worn out and was leaking oil as expected when they performed the pre-strip-down diagnostic test. Everything returned / refunded without issue, but I must admit to have dropped the ball a bit on this one...

But we do now have two lovely kittens, so all is all right in the world.
2020-10-26 08.52.31.jpg
 
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