Something to watch out for: loose turbo bolts!

**Timbo** · 09-11-2007, 12:55 PM

I mentioned in the dog-bone mount insert thread that I'd post a thread about an issue that has emerged with the Polo GTI, and which all owners -- especially those who track -- should watch carefully.

Rob (PoloGTi) was the first to alert us about this with his 'blown gasket' thread. At the time I thought it reflected poor VW dealer service rather than a technical problem with the car. That's not the case.

A few weeks ago, another Polo and I tracked at Winton. After about half a day, the other Polo came in, cooled down and then on restart, sounded like a truck! We located the problem to a leak at the joint where the exhaust manifold connects to the turbo inlet (at the back of the motor, about the centre of the firewall -- see the attached diagram).

As the other Polo owner -- a man of great virtue -- was dealing with the issue, I ran a few more laps (the language was too rich to stay and help him!!), came in, cooled down and....my car did the same thing. This was no coincidence! My turn to swear!

Long story short, two of the three 17mm bolts were loosening....and while you could tighten them (a bastard of a job! If the heat doesn't get you, the sharp edges of clamps and clips will), they would soon loosen.

Getting back home, I had the three bolts replaced (they are single use, anyway) -- this needs to be done by your dealer (assuming you have one who has a clue -- mine didn't) or a specialist VW shop. I also purchased a replacement gasket from APR (thanks Alex). Subsequently, all seems well, and that is the case with the other car, too.

However, I was worried this was simply treating the symptom and not the cause. Some research (search the 1.8T engine technical sub-forum on vortex with the terms loose, turbo, bolt) showed this was by no means rare for owners of cars with this motor -- Audis, Mk IV Golf GTI, Passats etc all reported problems. Just fixing the bolts did not seem always to resolve the problem permanently, even if crush washers, wired bolt heads or super hi-temp Loctite was used.

Loosening bolts usually indicate vibration and movement, and there's plenty of scope for that, especially with the Pog. So I am hoping the new APR dog-mount insert reduces this...and stops the bolts loosening.

Obviously, it's too early to confirm, but I would suggest fitting the dog mount insert is good insurance agaist the problem, especially if you track your car.

PS: Oh yes, a prize for the first person who finds their official VW dealer is aware of this issue and has something constructive to say about solving it!!

**pomme** · 09-11-2007, 01:12 PM

A little unrelated, but on the topic of loose bolts.

I always heard a rattle on the front right of my car, which i assumed was from the speaker install in the door, something was loose... but could never work it out no matter how many times i took it apart... once when i was under the bonnet, upon closing heard the rattle... hit the car a few times and worked out the front light was loose and rattling around, the bolt holding it in at the top was so loose it was close to falling out... tightened it up and never had any problems... with the light again.

However a few days back, i opened the boot, and a screw rolled out of the right hand side... i have no idea where it came from... no extra rattles... but not too excited about the build quality... and definately give the turbo bolts something to worry about.

**GT3** · 09-11-2007, 01:24 PM

Tim - good report and well done.

**Flaps** · 09-11-2007, 01:39 PM

Thanks for the heads up. Glad to hear it all is well.

I'll have seb have a look at mine next week.

**Guy_H** · 09-11-2007, 06:28 PM

If anyone gets stuck, its not the complete fix, but we have had some special high temp, super durable gaskets cut for the Polo's for this application.

It certainly helps, but does not cure the bolt loosening problem!

**PoloGTi** · 09-11-2007, 11:20 PM

Thanks Guy For your help talking me throught my bolt probs has not happened again yet so if it does ill be calling cheers for your tech support. Rob.

**DrewstA** · 09-09-2009, 02:28 PM

Hi guys.
Being a newbie here, i'm also a little concerned with my Gti (07, 30,00kms) which i bought just a week ago - with these loose turbo bolt issues.
Last night i lifted the hood up and tried to find both the turbo and these bolts.
Well, i didnt even get as far as the turbo! So many hoses and things. I knew roughly where to look (between manifold and firewall) but boy oh boy...

Would someone be ok to post a photo or two of both where the turbo actually is, AND these bolts (and what actually needs to be moved out of the way to actually get to them).
Many thanks in advance...

**noone** · 09-09-2009, 02:38 PM

Don't stress mate, if you cant feel it and can't hear it, I wouldn't bee too worried.

**AcoustiK** · 09-09-2009, 03:39 PM

And Plus I am assuming your car would be under warranty anyway, get the dealer to sort it out ASAP if it does happen.

**woosh73** · 09-09-2009, 03:42 PM

having a full time business on the side ( www.captain thread.com) problem : turbo bolts are loose. i caught up with h100vw ( top bloke ) . who showed me the problem

1. redo the thread with a helicoil to make the thread tighter
2. ( i would recommend this one ) - convert the bolt to a stud and use spring washers and nuts.

By the way if anyone wants anything fixed ( see my website ) mention that your a member and we'll look after you.