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Discussion Starter #1
Hi.
My Treg started to manifest some problems with the left hand side turbocharger. Some times it just cuts both of the turbos, only because of the No.2 turbo faulty code, and when it is an active error, even the output test cant move the control motor. When I fiddle around the connector and wires it comes back online, and stays for some time, so I think it is a connection issue. Bit the problem is, that the connector for the turbo is around a milimeter from the massive Banjo bolt of the steering pump, so I can't even disconnect it, and the cables are coming out of that connector at a 90 degree angle because of that bolt. I find this solution very sloppy, considering they have managed to route hundreds of cables and pipes without touching, and still leaving access to bolts. Here is the picture I took from under the car of the connector.
241151


Thanks lads.
 

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2005 Touareg V10 TDI
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Hi Steven, that does indeed look a bit chewed. Did you strip back the insulation, or did you find it like this?
If I were you, I'd replace both the connector and the cable from as far up as possible, although IIRC that might only be about 20 cm ...
To disconnect it, you have to either remove the banjo bolt for the power steering, or, probably better, remove two of the three screws that hold the actuator in place, so you can swing it clear of the banjo bolt.
The screws are fairly easy to get to with a 10mm spanner. When removing the connector, first push it ON firmly while depressing the hooks on both sides.
 

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Discussion Starter #3
I did remove the rubber insulation skirt, but I had to tear it clear, as the thick end part of it was too big to pass that gap. It was folded in on of itself at a 180 degrees and fixed with a quickbinder thig. I tried to hit it with some wd 40 but it doesn't seem to help. I am a bit afraid to remove the actuator, as the two turbos were sent to england for a refit, and the guy told me that the position of the actuators should not be altered. My problem is that banjo bolt, as it gives no room whatsoever, if I replace the connector and wires, the new one will be kinked severely as well. Is that the original state of things, or someone has been here before? Or it's just that they didn't consider the servo pump when they designed the turbocharger?
 

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2005 Touareg V10 TDI
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Well, consensus between people replacing actuators seems to be that the banjo bolt has to come out to disconnect the actuator, so I'm pretty sure they're all like this. Mine was also folded back on itself and zip tied, as you explain. I totally agree that this looks like a 5pm on Friday type of solution, when they could have easily moved the actuator 10mm further down and made the rod to the turbo equally longer, but what can you do...
 

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Discussion Starter #5
Thank you for your help. I was really interested if it is bodged, but I guess it is the must have cockup of this engine. Amongs others... I will drain the oil and see if I can find anything on the wires or the connector. Is wire fault a common problem with turbos, or usually the turbocharger itself that gives in?
 

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I'm no specialist, but my mechanic told me that it's "almost always" the actuators causing boost issues. Of course you should check the movement of the rods before installing new actuators, as sometimes the entire VNT mechanism seizes up, which then causes the actuator to fail. Adding a high-temp lubricant is a very cheap way to potentially prolong the life of the new actuators (although I kinda doubt that the turbo itself outlasts two actuators, considering I changed mine at 166k km...).
There is one guy over at VWVortex claiming that wiring can be an issue, and it won't cost you anything to double check before ordering expensive parts, but I don't think it's common...
Lots of great info on that thread anyway: VWVortex.com - V10 Turbo(s) cutting out
 
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