Might need a turbo for my '05 Passat

imo000

Top Post Dawg
Joined
Dec 13, 2005
Location
Cambridge
TDI
2009 M-B ML320 Diesel & '05 Passat TDI Manual 5-Speed
Sitting on the side of the road waiting for the wife to pick me up. Hard to say what happened until I get it home and dig in but initial best guess is that the turbo seals went and the engine started ingesting engine oil. Sudden power loss, then a huge clowd of smoke (James Bond kind) and then the engine had no power to go pass 60km/h. Didn't notice the smoke because it's pitch black on the back roads until I stopped. Engine sounds like it's preigniting/diesels/detonates if I touch the throttle. Idle hunts up and down then settles but the smoke is huge even at idle. I shut it down as quicly. There is smoke coming out of the oil filler cap. So I'm thinking, for now, that the turbo needs replacing. If anyone on this forum has a good used one for sale, I might need it. Will.know for sure in the next few days.
 

imo000

Top Post Dawg
Joined
Dec 13, 2005
Location
Cambridge
TDI
2009 M-B ML320 Diesel & '05 Passat TDI Manual 5-Speed
Pulled the codes with my OBDII reader and they are p2196 and p0299
 

imo000

Top Post Dawg
Joined
Dec 13, 2005
Location
Cambridge
TDI
2009 M-B ML320 Diesel & '05 Passat TDI Manual 5-Speed
P2196 is O2 sensor too rich and P0299 is underboost. So maybe the turbo siezed and the oil was pushed passed the splash seal. Will know more when I tow it home this evening and pull the boost tube off the turbo.
 

RichJetta

Veteran Member
Joined
Aug 7, 2010
Location
Oshawa, Ontario
TDI
2004 Jetta TDI-PD 5spd
I had smoke out the oil filler cap with a broken turbo shaft before it was going through the oil lines into the crank case.
 

imo000

Top Post Dawg
Joined
Dec 13, 2005
Location
Cambridge
TDI
2009 M-B ML320 Diesel & '05 Passat TDI Manual 5-Speed
Yup, the turbo shaft broke a few mm after the nut (cold side). Then the broken nut/shaft got sucked back into the impeller chewing it up and jamming the impeller. I'll post carnage pictures when I figure out how on the phone.

Anyone here has a good used turbo for sale for an '05 Passat TDI? I'm in the market for one. :)
 

imo000

Top Post Dawg
Joined
Dec 13, 2005
Location
Cambridge
TDI
2009 M-B ML320 Diesel & '05 Passat TDI Manual 5-Speed
I can get a good used stock one for $350.
 

imo000

Top Post Dawg
Joined
Dec 13, 2005
Location
Cambridge
TDI
2009 M-B ML320 Diesel & '05 Passat TDI Manual 5-Speed
Picked up a replacement one fromThe Source today. No shaft play, came with the maniford, EGT probe and EGR tube (it was easier for them to pull it as a unit since the engine was out). I had to use a "Thor" mini spedge to break off the aluminium compressor housing, the nut behing it was rounding off because of rust. BUT I got the stupid thing off last night. Haven't swore this much at a car in a very long time. 1.5L of oil came out of the intercooler and the car is still tilted the wrong way to fully drain it. The intake tube is full of impeller pieces too and I'm expecting the intercooler will be too. I'll reinstal the turbo tonight and then clean out all the pipes up to the intake manifold. The exhaust is full of oil too. It will be smoming like hell when everything gets buttoned up. :)
 

mrrhtuner

Veteran Member
Joined
Mar 29, 2011
Location
London Ont Canada
TDI
2003 Jetta Wagon TDI, 2015 Passat TDI, 2015 Touareg TDI
Imo, 1.5L of oil from IC?

So in other words, you could have had a runaway if it kept driving still?
 

imo000

Top Post Dawg
Joined
Dec 13, 2005
Location
Cambridge
TDI
2009 M-B ML320 Diesel & '05 Passat TDI Manual 5-Speed
I think it leaked so fast that it was pre egniting instead or running away. A little less leak and it might have been enough to runaway. I have no idea what shape the turbo was before this but it didn't consume much oil until the last oil change.
 

imo000

Top Post Dawg
Joined
Dec 13, 2005
Location
Cambridge
TDI
2009 M-B ML320 Diesel & '05 Passat TDI Manual 5-Speed
All fixed. Used dishsoap and went to the self serve car wash to clean out all the pipes and the intercooler. The tube under the radiator was flushed out with garde hose. I think I found the primary problem. The air filter was clogged and it was pulled in and then ripped. Probably something big got through the rip and the rest is history. The most fun was the burning out of the oil from the exhaust. Drove out of the neighbourhood as fast as I could but still some will have less issue with mosquitoes for this evening. I live near the countryside so headed to the corn field to get the exhaust clean. The smoke that came out was EPIC! :) kept it in 3rd at 85km/h for 15km before the smoke started to lessen. Another 5km more and everything was back to normal. The rear bumper, hatch and hitch are dripping oil. There had to be a litre or more oil just in the exhaust system.
 
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imo000

Top Post Dawg
Joined
Dec 13, 2005
Location
Cambridge
TDI
2009 M-B ML320 Diesel & '05 Passat TDI Manual 5-Speed
All the emission systems became ready a day after getting it running so decided to take the car for a camping trip to Watkins Glen. Have 525km on it now (90km was around town as a shakedown test). The catalytic converter looks like survived the oil bath too. Besides the turbo, engine oil and air filter, everything else was reused. The multilayer gasket between the turbo and the downpipe was wirewheeled and I a wrench I cut down the sides to loosen the oil feed line so that didn't need changing either. All in, the turbo was $350 and the oil plus the 2 filters was another hundred. It was due for an oil change anyways. Been 5K km since the camshaft replacement. Next in line is deleting the balance shaft module. Started gathering the needed parts.
 
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