1.6 CR (CAYC) Turbo Removal

[Lucero]

What can I say, I'm a cheap skate and whilst I could pay for some of the online repair manuals, hoping I get the right information, I thought I would ask here:

I need to remove the turbo from the 1.6 TDI CR 105 (CAYC) engine.

Hoping someone can point me to a guide.

In either case, what it looks like to me:

Remove O/S drive shaft
Drop DPF out
Remove Air Box and pipework
Remove EGR pipes
Remove heatsheilds
Remove oil feed pipes
Remove manifold/turbo

I'm just hoping to cover off anything else obvious I might have missed.

 

[tibor]

hello, idk if you read it, but did you manage to do it? do you have to remove drive shaft, drop dpf?

 

[Lucero]

I did, I managed it just by disconnecting and dropping the DPF out (the clamp and 3 bolts) and removing the drivers side drive shaft so that the DPF could drop down fully. The rest was actually pretty easy. Running 192bhp now

 

[tibor]

I did, I managed it just by disconnecting and dropping the DPF out (the clamp and 3 bolts) and removing the drivers side drive shaft so that the DPF could drop down fully. The rest was actually pretty easy. Running 192bhp now

uh and do i really need to take out dpf and remove driver shaft? im scared to do so haha. cant be done without that? loosen the dpf and cant be tucked away?

 

[Lucero]

Sadly not, you just can't get enough access to the manifold let alone the bolts (some of which are blind). All I did was unscrew the DPF clamp (from top of engine), remove the bracket from the rear of engine that holds the DPF up (couple of bolts) and removed the drive shaft so that the DPF could just drop down out of the way.

 

[tibor]

thanks mate, and can i ask why you removed turbo? did you swap for GTC1549VZ?

 

[Lucero]

thanks mate, and can i ask why you removed turbo? did you swap for GTC1549VZ?

I went for the GTC1552vz hybrid (slightly larger compressor 52mm instead of 49mm). It's absolutely transformed the car.

 

[tibor]

did you had to replace oil feed? i cant seem to find any oil feed that i need. isnt it 12mm banjo on the engine side, and m14 "nut" type (like oem has that end) ?or is it both banjo?

 

[Lucero]

did you had to replace oil feed? i cant seem to find any oil feed that i need. isnt it 12mm banjo on the engine side, and m14 "nut" type (like oem has that end) ?or is it both banjo?

I had a Borgwarner turbo so when fitting the GT, it came with the turbo/oil stand pipe and the oil return pipe (pictured)

 

[tibor]

thank you, one more thing, sorry for bothering you haha. do you have to drop the subframe to remove axle?

 

[Lucero]

thank you, one more thing, sorry for bothering you haha. do you have to drop the subframe to remove axle?

Nope, just the drive shaft and DPF. Probably an awful lot easier to get at it all by taking the subframe out, but you have to weigh up the time spent removing the subframe vs time spent in a smaller space

 

[tibor]

thank you, a little bit late haha. one more question if you allow me. when does the turbo actually charge? i mean at what rpm? now my stock turbo starts at 1500 to 2000. im wondering what about the bigger turbo. thank you

 

[Lucero]

thank you, a little bit late haha. one more question if you allow me. when does the turbo actually charge? i mean at what rpm? now my stock turbo starts at 1500 to 2000. im wondering what about the bigger turbo. thank you

This will be covered by whoever does the map, it will have to be live mapped but mine comes in around 1250 and heads off to over 3k now

 

[jdmsx]

Should make a thread for the build Lucero! Really interested in seeing what you’ve done to it. Hopefully planning on doing a hybrid turbo setup on my 2.0tdi later this year all going well!

 

[Tommy2281]

Hi mate . New to the Leon’s. Did I read right that your cayc is pushing 192bhp of a 1.6tdi. If so what did you do to gain this as want mine to be similar bhp