Turbo/Exhaust/EGR

Un4tural

Member
Hello All,

So next on my to do list will be Exhaust, Turbo and EGR work. (TDI 90 ATL)

As it seems to be single unit for exhaust I'll need to purchase a whole kit/replacement exhaust it seems, Flex pipe is leaking though MOT didn't pick up on it - or is it a better option to take it to exhaust specialist to just weld a new flex pipe in? As i'd be doing work i imagine replacement parts will be less than labour + flex pipe.

Will remove EGR and blank it/remove flap as it has been mapped out already but it leaks a bunch of oil over back of engine that comes in with exhaust.

Will massage in an oil catch to the breather pipe though exact positioning will be eye balled.

Finally i have a low mile good condition turbo to replace current one which either needs a clean or a rebuild, it was rebuilt in 2012 so wouldn't expect it to be knackered but wouldn't be too surprised either as some of the maintenance paperwork did mention there being no oil in the motor.

Hopefully this will carry me over emissions wise next MOT by which point i should have space to take it apart properly and give it a good clean/refurb.

i am in SW London - if you have any recommendations/tips they'll be very welcome as i'll be working with car on axle stands and Turbo access seems to be less than pleasant, any recommendations will help to make life easier.

Probably good idea to check on re-doing the heat shields as well, but will most likely end up sticking those on using either zip ties (stainless steel?)as all the bolts and nuts are rusted clean off and fabricating some from a sheet of material when i find some.

Main problem is that turbo is slow to spool up causing a puff of smoke, sometimes lagging up to 3k RPM in second gear, but seems to struggle in general, figure it'll be easier to just go and do all of it at once than faff about separate + will measure vacuum line as well in case that is imploding and not doing it's job. Could be a number of things but again might as well just get the remainder of bits and get it all done and dusted.
 
There's some interesting info on turbo alternatives here...
 
Here's a thread i started about the turbo side of things, has a good guide to the turbo cleaning at #11.


i'd be interested to hear if you upgrade your exhaust, on my to do list...
 
Here's a thread i started about the turbo side of things, has a good guide to the turbo cleaning at #11.


i'd be interested to hear if you upgrade your exhaust, on my to do list...

Wow you've been at it for a while - did it resolve the poor mpg numbers? Mine still pulls well and good but it is about 40-42mpg no matter what - i suspect the VGT but could be a few things, seems very temperamental and lady like as sometimes it is black smoke and sometimes white whilst it lacks power until turbo picks up and then it pulls just fine, sometimes it takes a while sometimes just a moment and sometimes it seems to work fine :D Figure it is 160k might as well just go over everything and parts total isn't that bad - tried to get to it a while ago and access is pretty horrid especially after looking at Mrs. A4 with turbo and EGR right there nice and accessible with barely a need to remove engine shield!

Did notice clamp in flex pipes for sale with bolt/clamp things that clamp onto existing pipe, so cutting mine could be an option the massaging the replacement and doing up the clamps on each end so might save some time and money with that as rest of exhaust isn't that bad, though a nice stainless one does sound nice to know that i have...

@damadgeruk now i want to get a gtd1244vz turbo! Seem to be quite a few available at very reasonable prices too! But it's probably wiser to just bolt on the low mile turbo i have in storage instead until i have tools/space to make gtd1244vz fit. That thread is extremely helpful and a huge help with list of parts needed, luckily i have some copper nuts already among other bits.


Any recommendations on exhaust? Current one isn't rusty or crusty just the flex is blowing a bit which is why i am intrigued by the clamp in flex option. (Such as this )
 
@Un4tural I recently bought this cheaper version of the flexy (stainless option) though I've not fitted it yet. I'm planning on making my own ATL stainless exhaust (I like to make life difficult). ;)
 
Wow you've been at it for a while - did it resolve the poor mpg numbers? Mine still pulls well and good but it is about 40-42mpg no matter what - i suspect the VGT but could be a few things, seems very temperamental and lady like as sometimes it is black smoke and sometimes white whilst it lacks power until turbo picks up and then it pulls just fine, sometimes it takes a while sometimes just a moment and sometimes it seems to work fine :D Figure it is 160k might as well just go over everything and parts total isn't that bad - tried to get to it a while ago and access is pretty horrid especially after looking at Mrs. A4 with turbo and EGR right there nice and accessible with barely a need to remove engine shield!

Did notice clamp in flex pipes for sale with bolt/clamp things that clamp onto existing pipe, so cutting mine could be an option the massaging the replacement and doing up the clamps on each end so might save some time and money with that as rest of exhaust isn't that bad, though a nice stainless one does sound nice to know that i have...

@damadgeruk now i want to get a gtd1244vz turbo! Seem to be quite a few available at very reasonable prices too! But it's probably wiser to just bolt on the low mile turbo i have in storage instead until i have tools/space to make gtd1244vz fit. That thread is extremely helpful and a huge help with list of parts needed, luckily i have some copper nuts already among other bits.


Any recommendations on exhaust? Current one isn't rusty or crusty just the flex is blowing a bit which is why i am intrigued by the clamp in flex option. (Such as this )
I had a go at fitting one of these clamp on flexible pipe, I couldn't get it to fit, I think others have struggled too.
Cheers
 
PS, yes the mpg improved alot, could get high 50's if careful, usually around 50 average for around here.
 
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