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VW B5 Passat TDIs This is a general discussion about B5 Passat(>98 (2004-2005 in North America)). Non TDI related postings will be moved or removed.

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Old May 22nd, 2020, 21:50   #1
Dan99TDI
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Default Turbo Outlet hose question

Hi TDI Club,
I bought a B5.5 passat tdi knowing it had a P0299 and having read about it pretty thoroughly.

I have a potential culprit in the turbo outlet hose that doesn't look right- here is a picture I snapped. I'm thinking air may be leaking past the hose where the housing has a gap from the hose- but I don't know how this hose is supposed to seal, I haven't been able to find any pictures online.

https://drive.google.com/file/d/1dgc...ew?usp=sharing

To cover the bases, The engine is producing vacuum, which at idle smoothly moves the VNT lever to the stop and holds it there- registering about 20" of mercury.
Thanks!
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Old May 22nd, 2020, 23:52   #2
Dan99TDI
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For anyone looking at this in the future, I found this video on replacing the hose, clarifies the sealing mechanism.
https://youtu.be/kiFwRnyXeEQ
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Old May 23rd, 2020, 09:07   #3
Dan99TDI
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Found my OBD Dongle, cleared the code, and the car runs great.

Graphed the boost on a quick jaunt up my backroad, and it seems to be creating and controlling boost.
https://photos.app.goo.gl/cMPykAoMongXi9iw9

I'm running torque pro, so I don't seem to be able to see requested boost.

The only thing I can think at this point is either:
1: the computer is referencing another sensor and thinking the comparison doesn't make sense
2: The computer thinks the boost is taking too much time or control to make the boost
3: Magic.

I guess I'll keep updating this in hopes it'll help someone else down the road.
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Old May 24th, 2020, 08:13   #4
auntulna
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Yikes! That is some improvising you got there, I wouldn't want to leave town with that setup. It looks like whoever was there didn't want to pay for the right hose, or lost the clips, or one of the clip retainers broke off.
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Old May 24th, 2020, 09:33   #5
Dan99TDI
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Yeah looks that way- there's actually a little lip that might be the swaged oring holder, and the hose clamp may be a poor replacement for the clip. I have some time today so I'll be checking the intake tract.
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Old May 25th, 2020, 12:17   #6
Dan99TDI
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Well, I drove it yesterday and noticed an interesting facet.

I only get the code under moderate throttle- cruising down the highway at 75 seems to be the Achilles heel. If I hammer down on it, it seems to run great.

This implies to me a relatively small boost leak.

New o-rings and retainer clip about to be ordered.

Happy Memorial Day!
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Old May 27th, 2020, 19:12   #7
Passat'n Adventure
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Quote:
Originally Posted by Dan99TDI View Post
Well, I drove it yesterday and noticed an interesting facet.
I only get the code under moderate throttle- cruising down the highway at 75 seems to be the Achilles heel. If I hammer down on it, it seems to run great.
This implies to me a relatively small boost leak.
New o-rings and retainer clip about to be ordered.
Happy Memorial Day!
Don't forget to order the correct hose too.... This setup looks undersized for the air going through it. The original hose has a slight taper to it and metal ends on it that will seal correctly - with the correct clips. The top and bottom are different clip numbers. I can tell you that from experience.
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Old May 31st, 2020, 14:58   #8
Dan99TDI
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Pulled individual pieces apart, they all look to be correct.

Pulled the clip off the turbo outlet, its the correct hose and the clip just needed to be bent slightly to hold the hose.

Built a home made smoke leak tester and could not find a leak.

Took another boost log against rpm, and it builds 2.5 bar (absolute) but it doesn't come in until 3000 rpm.

Turbo was supposed to be new, and looks relatively new.

Changed the fuel filter and it now takes longer to set the code, but it still sets.

I'm left to wonder about injectors, plugged cats...
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Old June 2nd, 2020, 09:19   #9
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The problem is manifesting only at light throttle, indicating a lack of boost at low engine speed and load. Most likely culprit is the vane control system. I'd check vacuum lines again, and possibly replace the N75.

Plugged cat would be worse at high speeds and bad injectors are virtually unheard of, at least until you reach 400-500k.
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Old June 2nd, 2020, 09:24   #10
oilhammer
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Or some junk Chinaboost replacement turbo. The OEM Garret turbos are not high failure items. Lots get replaced for no reason other than someone could not properly diagnose a boost system.

I've had to take so many of those off and chuck them in the recycle bin.
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Old June 2nd, 2020, 09:59   #11
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Quote:
Originally Posted by QuickTD View Post
The problem is manifesting only at light throttle, indicating a lack of boost at low engine speed and load. Most likely culprit is the vane control system. I'd check vacuum lines again, and possibly replace the N75.
Plugged cat would be worse at high speeds and bad injectors are virtually unheard of, at least until you reach 400-500k.
Yeah, the plugged cat didn't make sense after I thought about it.

Glad to hear on the injectors.

The turbo appears to be genuine Garrett.

I guess I'll run through the vacuum diagnostics once more. Can the turbo be clocked against the vane system where it could appear in spec from the actuator but actually be out of spec?

Also, I'm thinking of shortening the actuator despite it appearing in spec- am I correct in thinking I can't really do any damage by doing this as long as I don't overboost it?

One check I did to make sure I wasn't over speeding the turbo- I compared MAP readings to boost and rpm- at 3500 rpm and 2.5 bar i was seeing ~140g/s which matched conditions closely enough for me to have a little peace of mind
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Old June 2nd, 2020, 10:16   #12
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You can work the VNT actuator with VCDS in the Basic Settings. This is the quickest, easiest, least troublesome way. And on the BHW, it is super easy to actually SEE it from above. That is how you check the control side vacuum. It takes 20 seconds.

If you do not have the correct scan tool, get one. You'll be way ahead.

I use a smoke machine to check for boost leaks, although in some cases the smoke machine's meager 3 PSI or so simply is not enough to reveal one that perhaps "opens" when under major boost, like a split in one of the charge air hoses. But it makes quick work of finding leaking quick connects, be it from the tabs being worn through (especially common on the BHW's 'S' shaped hose off the turbo) as well as the seal rings on all the connections, and the all-too-common damaged from a crash cracks in the intercooler.
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Old June 2nd, 2020, 21:34   #13
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Quote:
Originally Posted by oilhammer View Post
If you do not have the correct scan tool, get one. You'll be way ahead.
Am I correct in thinking Ross-tech is the go-to cable and software?

This was on my list anyways. Might as well move it forward.
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Old June 3rd, 2020, 03:07   #14
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That seems to be the gold standard, yes. That is what I use, and many of us here use, so if you want our help that tool will be very beneficial.
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Old June 3rd, 2020, 09:17   #15
Dan99TDI
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Well, digging into it this morning I figured out that appearances aren't always what they seem. I do appear to have a Chinese knock off turbo, with the actuator adjusted all the way to the top to boot. I should've looked closer.
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