new 2006 Jetta TDI with Exhaust leak

DCR

Active member
Joined
Sep 19, 2010
Location
Coolidge, Az
TDI
2006 Jetta TDI
I just bought a 06 Jetta TDI that was really clean 140K on the clock, one owner, good carfax report, all the options etc. Wasn't too worried about the miles since its TDI and dude was commuting a few times a minth between Cali and Az for work.

Problem is, I drove the crap out of it during test driving and it seemed to run strong, no issues that I noticed. Once I got it home and was driving it around in the cool night with the wondows down I heard what sounded like an exhaust leak. Next morning I got it in the air, pulled the skid plate off and started looking. It seems like its a leak after the turbo. Its a strong air leak, but it doesnt sound like engine noise if that makes sense. It also only seems to leak if you are on the gas like accelerating from a stop or reving. I can also see a bit of oil around the housing on the turbo. I know from what I have read it seems that its a common problem for the oil line threads to leak.

Another question is... Is there a good write up for changing the timing belt? I want to knock out all the maintanence on this since I dont know its history. I have found the write ups for the older ones, but not the 06ish ones.

Thanks guys! Found a ton of great info here already!
 

raabusmc

Member
Joined
Sep 29, 2010
Location
Dallas
TDI
2005.5 1.9L
I am in the same exact boat. 2005.5 Jetta TDI, ran really well during test drive. 135k miles, one-owner, drove to/from Texas:Canada. Miles weren't a big deal. Bought it 9/22/2010 and on 10/2 I've got what appears to be an exhaust leak. Its really noticeable upon acceleration and when cold/cool, took it to a muffler shop and he lifted it in the air and couldn't find anything while down on the ground either. He suggested I take it to the dealer. No thanks. I ran it up to Advanced Auto Parts, and the guy says its definitely an exhaust leak. I'm going tomorrow to get a second opinion from a suggested exhaust specialist.

What was your outcome? Any ideas?
 

D-Cell_Mekanick

Veteran Member
Joined
May 23, 2009
Location
Sandwich, IL
TDI
2015 Honda Civic SE
I am in the same exact boat. 2005.5 Jetta TDI, ran really well during test drive. 135k miles, one-owner, drove to/from Texas:Canada. Miles weren't a big deal. Bought it 9/22/2010 and on 10/2 I've got what appears to be an exhaust leak. Its really noticeable upon acceleration and when cold/cool, took it to a muffler shop and he lifted it in the air and couldn't find anything while down on the ground either. He suggested I take it to the dealer. No thanks. I ran it up to Advanced Auto Parts, and the guy says its definitely an exhaust leak. I'm going tomorrow to get a second opinion from a suggested exhaust specialist.

What was your outcome? Any ideas?

Just a guess, EGR Cooler?
 

janascii

New member
Joined
Apr 28, 2010
Location
Rolla, MO
TDI
06 Jetta (BRM)
My guess would be EGR... my 06 has the same hissing sound that is very prevalent upon acceleration up to about 2300 rpm... only a second or so... then it goes away.
 

raabusmc

Member
Joined
Sep 29, 2010
Location
Dallas
TDI
2005.5 1.9L
I took it to "V-Dub Guys" in Irving, Tx. John stated he's almost positive it a camshaft/lifter issue with a quote of $1600 ish. WOW, I thought, so I stopped by another exhaust on my way home and the lifted it and said it was exhaust least at the turbo. He quoted $300. With the differences in opinion, I opted to take it to Autobahn VW in Fort Worth (The original dealer and has all maintenance records from original owner.) As I looked through the service history during the dianosis, I noticed it had already been at this dealership for EGR replacement at 117k, and lower boost pipe seal replacement at 119k. The Master technician, Jeff, called back this morning and stated it is not a turbo issue or exhaust leak. He'd have to pull the engine apart further to diagnose. The service adviser, Dennis, called and stated Jeff says its a camshaft and lifter issue amongst some other things and suggests I come in tomorrow A.M. to physically see it all. The service advisor stated it'd be about $5000.

I paid $9000 for the car, pretty much what its worth, and to sink in an additional $5000 has me speechless.

What are your suggestions?
Mention to the dealership, that they just recently had it pulled apart with no mentions in documentation?
Ask for a manufacturer rep's assistance, being that it's only been serviced at Autobahn?
Take it back to V-Dub Guys, with the hopes that they don't find more issues and charge more?

PLEASE HELP. I'm at a loss
 

Jnitrofish

Veteran Member
Joined
Jun 24, 2009
Location
Texas
TDI
2005.5, 2005.5, and 2006. 5m, 5m, and DSG.
How about take it to Steve Glover in Fort Worth? You will be at a loss, but much less so than $5000. Autobahn will be throwing parts (needed or not) at the car to save time on your bill, and $5000 is quite possibly just where it begins. And I cant speak for the quality of service at V-Dub.

Trusted mechanics list said:
TechnicalDieselInnovations
Steve Glover (mtbr297 on TDI club)
mtbr244@hotmail.com
(817) 244-7747 cell (817) 915-4063
Fort Worth, TX
At least consider giving Steve a call to see if he can help.
 

raabusmc

Member
Joined
Sep 29, 2010
Location
Dallas
TDI
2005.5 1.9L
How about take it to Steve Glover in Fort Worth? You will be at a loss, but much less so than $5000. Autobahn will be throwing parts (needed or not) at the car to save time on your bill, and $5000 is quite possibly just where it begins. And I cant speak for the quality of service at V-Dub.



At least consider giving Steve a call to see if he can help.
I will do that. Thanks, I am going to shoot him an email right now tonight.
 

2footbraker

Veteran Member
Joined
Sep 6, 2005
Location
Ontario, Canada
TDI
06 Jetta, 01 Golf
Are you sure there's anything wrong at all? If you're on the go pedal with the windows down you will hear a whooshing when the turbo is spooling. If you have a boost gauge, you should have a stable max boost at 15 psi. You should see a lot of soot around the egr cooler if it's leaking. A bit of oil around the compressor inlet is not a big deal.
 

raabusmc

Member
Joined
Sep 29, 2010
Location
Dallas
TDI
2005.5 1.9L
Are you sure there's anything wrong at all? If you're on the go pedal with the windows down you will hear a whooshing when the turbo is spooling. If you have a boost gauge, you should have a stable max boost at 15 psi. You should see a lot of soot around the egr cooler if it's leaking. A bit of oil around the compressor inlet is not a big deal.
Just got back from the dealer and they let me go look at the engine torn apart. The cam has a flattened worn out spot on one area, a rough area on another and 2 worn streaks on another. It was suggested to replace the entire head because they couldn't see the valve. They were going to draft up 3 separate quotes.

1. Head replacement, with Timing Belt and water pump replacement.
2. Just the head replacement (to fix the cam issue)
3. Just the cam/lifters replacement.


Should I request the manufacturer's rep 800 # for assistance?

Dump the car on a paid-off trade?

Seek other assistance? i.e. Tim's German Auto, complete rebuilt engine, etc.?
 

oilhammer

Certified Volkswagen Nut & Vendor
Joined
Dec 11, 2001
Location
outside St Louis, MO
TDI
There are just too many to list....
Holy crap, what the eff is with these dealers???

All it needs is a cam and lifters, cam bearings, cam cap bolts, and injector rocker bolts. I'd prolly want to do a full t-belt job while in there too.

It does NOT need a head. I guarantee it.
 

theinternot

Veteran Member
Joined
Mar 25, 2010
Location
So Cal
TDI
2012 Passat TDI SE
Could you elaborate on the noise you are hearng.

Is it raspy, metal on metal, spinning pie tin rubbing together noise?

Is it a high pitch whistle?

Is it a bup bup bup bup sound?


I would very much like to know as I am trying to diagnose a noise on my car that I can't seem to isolate.

Thanks

I just bought a 06 Jetta TDI that was really clean 140K on the clock, one owner, good carfax report, all the options etc. Wasn't too worried about the miles since its TDI and dude was commuting a few times a minth between Cali and Az for work.

Problem is, I drove the crap out of it during test driving and it seemed to run strong, no issues that I noticed. Once I got it home and was driving it around in the cool night with the wondows down I heard what sounded like an exhaust leak. Next morning I got it in the air, pulled the skid plate off and started looking. It seems like its a leak after the turbo. Its a strong air leak, but it doesnt sound like engine noise if that makes sense. It also only seems to leak if you are on the gas like accelerating from a stop or reving. I can also see a bit of oil around the housing on the turbo. I know from what I have read it seems that its a common problem for the oil line threads to leak.

Another question is... Is there a good write up for changing the timing belt? I want to knock out all the maintanence on this since I dont know its history. I have found the write ups for the older ones, but not the 06ish ones.

Thanks guys! Found a ton of great info here already!
 

raabusmc

Member
Joined
Sep 29, 2010
Location
Dallas
TDI
2005.5 1.9L
Holy crap, what the eff is with these dealers???

All it needs is a cam and lifters, cam bearings, cam cap bolts, and injector rocker bolts. I'd prolly want to do a full t-belt job while in there too.

It does NOT need a head. I guarantee it.
Should I just get a parts ONLY quote for:
cam and lifters, cam bearings, cam cap bolts, and injector rocker bolts

and get with another specialist? Or do you believe another specialist can get those parts at a discounted rate?
 

oilhammer

Certified Volkswagen Nut & Vendor
Joined
Dec 11, 2001
Location
outside St Louis, MO
TDI
There are just too many to list....
Should I just get a parts ONLY quote for:
cam and lifters, cam bearings, cam cap bolts, and injector rocker bolts

and get with another specialist? Or do you believe another specialist can get those parts at a discounted rate?
First you need to get the car AWAY from those crooks. Look up trusted TDI mechanics in your area in a sticky on this forum, even if it means towing it half way across TX.
 

Jnitrofish

Veteran Member
Joined
Jun 24, 2009
Location
Texas
TDI
2005.5, 2005.5, and 2006. 5m, 5m, and DSG.
First you need to get the car AWAY from those crooks. Look up trusted TDI mechanics in your area in a sticky on this forum, even if it means towing it half way across TX.
I already gave him Steve Glover's info above, and strongly suggested calling him, because I know the dealer is going to use scare tactics to get all the money and parts they want. raabusmc you need to grab them by the balls, and tell them exactly what they are going to do, or else they will walk all over you. I again suggest getting the car out of there and to Steve, because I havn't heard of anyone having to grab Steve's balls recently.

Let the guy working on your car supply the parts, that way he knows the source and manufacturer of the parts and has experience that there is not a chance that any of them will fail and make you hate him (and lawsuits etc).
 
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DCR

Active member
Joined
Sep 19, 2010
Location
Coolidge, Az
TDI
2006 Jetta TDI
Mine turned out to be the EGR cooler as suggested. I got the parts from worldimpex.com as was suggested in this post. http://forums.tdiclub.com/showthread.php?t=292929
Cost me a bit over 300 bucks and about all day last saturday. It wasnt exactly what I would call simple, but it wasnt the worst job in the world.

I know the power increased dramatically after the repair. I cant tell you about the MPGs yet, havent ran a full tank through. It was getting about 34 with the leak. Im hoping that goes up a good bit.

What are the signs simptoms of the cam issue that this car has? Is there any way to diagnose it without taking things apart? Mine seems to be running fine, just curious what to watch for.
 

raabusmc

Member
Joined
Sep 29, 2010
Location
Dallas
TDI
2005.5 1.9L
Spoke with Steve and am moving forward with an Oct 25th service at Steve's. Autobahn service advisor, Brad, had a horrible attitude and lost my business for life. Trusted TDI mechanics from this point forward. Is there an supermarket or upgraded cam that's resistant to this issue?
 

raabusmc

Member
Joined
Sep 29, 2010
Location
Dallas
TDI
2005.5 1.9L
Spoke with Steve and am moving forward with an Oct 25th service at Steve's. Autobahn service advisor, Brad, had a horrible attitude and lost my business for life. Trusted TDI mechanics from this point forward. Is there an supermarket or upgraded cam that's resistant to this issue?
*aftermarket not supermarket (spell correction)

And I will post a video with sound when the engine accelerates later tonight
 

2footbraker

Veteran Member
Joined
Sep 6, 2005
Location
Ontario, Canada
TDI
06 Jetta, 01 Golf
The Colt Cams BEW stage 1 or 2 *may* be less resistant due to the more relaxed lobe profiles. Coupled with Franko6 bearing mods and a good 5w40 oil you should be good to go for a long time, although there's still no hard evidence for anything.
 

raabusmc

Member
Joined
Sep 29, 2010
Location
Dallas
TDI
2005.5 1.9L
The Colt Cams BEW stage 1 or 2 *may* be less resistant due to the more relaxed lobe profiles. Coupled with Franko6 bearing mods and a good 5w40 oil you should be good to go for a long time, although there's still no hard evidence for anything.
I will get with Steve on the Colt Cams & Franko6 mods to see if that's something we can get done. Here is the noise of what's happening to my engine. My mic sounds really distorted though.

http://www.youtube.com/watch?v=P0euv5trurw

Although it sounds identical to this previous video:

http://www.youtube.com/watch?v=QuAfEKx84F4&feature=related
 

raabusmc

Member
Joined
Sep 29, 2010
Location
Dallas
TDI
2005.5 1.9L
Steve's got some Colt Cams on order that haven't come in yet. We discussed going this route + chipping and getting timing belt / water pump again while we're in there.

Excited and let down at the same time.
 

raabusmc

Member
Joined
Sep 29, 2010
Location
Dallas
TDI
2005.5 1.9L
The Colt Cams BEW stage 1 or 2 *may* be less resistant due to the more relaxed lobe profiles. Coupled with Franko6 bearing mods and a good 5w40 oil you should be good to go for a long time, although there's still no hard evidence for anything.
Are there any other mods you'd do while you were in there? Basically, if you were in this situation, what would you have done while we got it under repair?
 
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raabusmc

Member
Joined
Sep 29, 2010
Location
Dallas
TDI
2005.5 1.9L
Well I saw the TDI Club recommended mechanic and he noticed some rattle coming from the flywheel as well. Would have me paying an additional $3000 (without KermaTDI, EGR Delete & Timing Belt) to get this used car back up and functional with no promises of reliability in the future.

TRADED this 2005.5 TDI in for a 2010 Honda Fit SPORT, no more worries, no more special care and maintenance.

Good luck guys.
 
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