2004 Golf TDI new turbo

[tel]

hi folks,

I've got a 2004 TDI with just shy of 200,000 miles. mechanic says it needs a new turbo and intercooler. that's a pretty big ticket item for me, so I'll be getting another opinion before I go ahead. assuming those things do need replaced, does it make sense to use stock parts or something aftermarket?

I'm most interested in fuel economy and reliability. I drive really conservatively, so I'm not interested in making this into a race car. it looks like prices for the original equipment and aftermarket stuff are pretty comparable, though this looks substantially cheaper than the $1300 I've been quoted for a stock replacement.

either way, this will be something I pay somebody else to do, as I have neither the time nor the wrenching skills/tools to do it myself.

thanks.

[Daox]

Congrats on the new wheels.

I would get your own parts from a salvage yard and put them on or have them put on.

[tel]

I like that idea. I've gotten some things at salvage yards before, but they've been relatively simple parts that I felt better at evaluating. trying to determine whether a turbo and intercooler are in good shape is fairly intimidating, though.

still beyond my wrenching capability, though. will many mechanics install salvage parts? will they ever warrant them?

[Daox]

Some will install salvage yard parts, I don't think all do. I highly doubt that any will give you a warranty on them.

[tel]

I'll try the salvage route first. it makes me a little nervous, but it would be a better use of limited resources (on both micro and macro scales).

let's suppose that fails and I buy new/rebuilt. will any aftermarket turbochargers increase fuel efficiency?

[oil pan 4]

Get an after market intercooler and pipin system if you can.
I have examined the turbo and intercooler piping on a jetta and found it to be totally inadequate. I bet the golf isn't much different.
The more air you can feed a diesel engine the better fuel economy it will get.
The KKK turbo is a pretty good turbo, not surprised it lasted 200k milesa bigger turbo may increase fuel milage depending on your application.
If you are going to do city or mixed driving stick with the stock turbo or a stock upgrade. If you are going to be doing mostly highway driving go bigger.

[tel]

seems reasonable, but please pardon my ignorance: what do you mean by "stock upgrade"?

[skyking]

he means a stock turbo from a different engine.
If you seek the same or better economy and are happy with the power, go back with an equivalent unit. I have played the turbo game on my TDI beetles.
With the VGT system, they spool great and have enough headroom for a moderate power increase if you choose to do so down the line.
Put in a bigger turbo and it will not be as responsive to small changes, and I took a ~3% hit when I went up to a hybrid 17/22, with the same tune.
I ended up going all out and lost probably 4~5%, or 2~3 MPG to gain seriously boatloads of power. Call it my 46 MPG midlife crisis .

[skyking]

I'm more than a little curious about the intercooler diagnosis. Unless it is cracked or holed in some way, it should be serviceable. Clean out the engine oil from the insides and the dirt from the outsides and go baby go. Mine is still original in both cars.
If you are close enough I'd do the turbo and intercooler swap for you.

[oil pan 4]

Something that will fit in the same place as the old one with minimal adaptors uses most of not all the original equipment.

For example the GM high performance parts aluminum cylinder heads going on my 8 liter big block Chevy are a stock up grade over the cast iron smog era heads it originally had.