Thread: 300tdi down on power

Turbo core arrived yesterday, so I got onto removing the old one this afternoon.

I was originally hoping I might be able to just remove the old core in situ and fit the new one.
Quickly became apparent that wasn’t going to happen as the bolts clamping the turbo to the exhaust manifold/housing wouldn’t budge.

So off with the manifolds and onto the bench for some butchery.

When I turned the exhaust manifold upside down it was blindingly obvious what the boost issue was.



So - I definitely feel like a bit of a goose for not picking that up while troubleshooting. Particularly when it was suggested I check the wastegate wasn’t seized (and I didn’t).
Ah well - such is life……
Since I’ve come this far I’ll fit the new core although the original one looks and feels perfectly fine.

I had to cut the heads off 3 of the clamp bolts to remove the old core. Managed to get one of the 3 out with heat, penetrant and vice grips, but ended up having to weld nuts onto the last 2 with the MIG to get enough leverage on them.

Steve

Oh dear Steve- a $470 C-clip! Don't tell your wife.

Yeah - *it happens.
I could always just throw the original one back in and flog the new core off, but knowing my luck it would crap itself 2 months down the track.

Just have to write it off as preventative maintenance…

Steve

Just a couple of hints for anyone doing their first turbo core on a 300tdi.

1. Don’t even think about trying to replace the core without removing the manifolds.
Just jump in and pull the manifolds at the start - it’s MUCH easier to do the turbo change on the bench.

2. Very likely you will need replacement clamp bolts for the core - particularly if it’s the original turbo that’s been on there for 20+ years. I ended up cutting the heads off mine with a grinder and welding nuts onto the remaining stubs to be able to remove them.
I’d also suggest having new studs and nuts for the manifold to down pipe flange joint in case they need butchery to remove.

3. Helps to have a decent pair of 90deg internal circlip pliers to remove the circlip on the compressor housing. It’s a big bugger, and tapered so it locks in pretty tightly. Would definitely be a struggle without the pliers (and I’m usually pretty good with alternative butchery).

Steve