Turbocharger TDI AMF 75 Repair

[Chris Warren]

Have you got a part number please for the gasket you have already used? The triangular one between the turbo and exhaust manifold. I’m having trouble finding one, can’t even find it on a parts diagram.

I don’t think there is one. I wire brushed both mating surfaces and then used a fine grain wet and dry with WD40 to get as smooth as possible.

 

[Little Dog]

The AMF turbo diagram is notoriously bad as it depicts a 4 cylinder manifold and corresponding turbo off the 1.9tdi, although the listed parts appear to be correct.

However, if you really squint at the parts list -

https://www.lllparts.co.uk/catalogs/audi/RDW/A2/248/1/145/145050

there is a non-numbered (and not depicted!) item between the turbo units and the other parts - see red arrow.

looking up this part number shows that it appears to be common to other tdi Audis of the same era doing the same sort of role and it looks like the right type of shape to be the part you are looking for.

View attachment 132594

Thank you, that’s the one. I have an Elring in my basket at AutoDoc .

@Chris Warren there is one, check out 059253115.

 

[rotifer II]

Hello All,
Time to get back to working on cars.

Turbo is finally back on the TDI after a long period of inactivity.

 

[rotifer II]

Priming the oil feed pipe​

Engine oil can be loaded into the top of the turbo before replacing the oil feed pipe using a small syringe.
The car could sit for a few days before you get to reassembling it fully meaning it is important to prime the oil feed pipe and turbo before starting the car in all situations.

Achieved by disconnecting the injection wiring loom cylindrical connector where it is attached to the side of the engine.

And cranking the engine in short bursts numerous times until you feel confident that it has built oil pressure in the feed line to the turbo.

 

[CrispyEdd]

How does it drive?

 

[rotifer II]

How does it drive?

Its 10pm Sunday 9th March and I have spent another great day working on this car.
The front end is back on the ground for the first time in what feels like 6 months.

I've just compiled a list for when I put the back wheels in the air tomorrow.
Rear silencer & heat shield
Tank strap
Fuel filter housing
Fuel cooler
Brakes
Stub axles
Spring bushes
Shock bump stops
Rear bumper
Tow bar refurb
Boot vents

it is never ending

 

[rotifer II]

Removed the injector loom electrical connector, glow plugs and began priming the oil pressure 5 times resting between each 10 second burst on the starter motor.

Engine started on the first turn.
The back box has been removed for servicing so it is louder than usual.

Higher rpm due to it being a cold this morning.

Apologies for the pulsing video footage when the engine starts

 

[Chris Warren]

Priming the oil feed pipe​

Engine oil can be loaded into the top of the turbo before replacing the oil feed pipe using a small syringe.
The car could sit for a few days before you get to reassembling it fully meaning it is important to prime the oil feed pipe and turbo before starting the car in all situations.

Achieved by disconnecting the injection wiring loom cylindrical connector where it is attached to the side of the engine.

View attachment 135599

And cranking the engine in short bursts numerous times until you feel confident that it has built oil pressure in the feed line to the turbo.

When I did a recent cylinder head gasket I removed the glow plugs and cranked the engine over for two 30 second bursts to circulate the oil. Good practice