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Thread: T5 turbo replacement

  1. #1
    Join Date
    Jun 2013
    Location
    Newcastle NSW
    Posts
    10

    T5 turbo replacement

    Just wondering if any of you have replaced the turbo on your T5. My 2004 2.5 AXE is displaying some symptoms that the turbo might be on its way out. I have searched these forums without success but found on the UK T5 forum that turbo failure is very common.
    my T5 started going into limp mode only on 1 hill in 3rd gear whenever I accelerated too much. This has become more frequent and now happens on any hill to the point that I have to drive very steady up hills so that it doesn't go into limp mode. I haven't had the codes read yet and am booked into a mechanic next week but the uk forums indicate that limp mode is often caused by overboost which is usually associated with the vanes in the turbo becoming stuck and requiring a rebuild or replacement.
    Another symptom that has only just started is a high pitch squealing which only happens on boost and only sometimes. When it squeals it doesn't accelerate anywhere as well as normal.

    I should know next week if it is the turbo as I know there are so many varying reasons for why our VWs do what they do. If I do need to replace a turbo I want to know my options on aftermarket or factory, availability, cost, etc.

    I am booked in for 180,000 km service which I am not expecting to be cheap, so with the addition of a new turbo or whatever else could really blow the budget.

    I will let you know the outcome.



    Paul.

  2. #2
    Join Date
    Dec 2008
    Location
    Sydney/Canberra
    Posts
    5,523
    Users Country Flag
    Also check for a cracked exhaust manifold around cylinder #1 runner at the flange.
    '07 Transporter 1.9 TDI
    '01 Beetle 2.0

  3. #3
    Join Date
    Feb 2008
    Location
    Adelaide,Oz
    Posts
    374
    Turbo limp mode
    Diagnosing and Fixing Limp mode for A4 1.9TDI - TDIClub Forums

    Does the vehicle require oil topups between services?ie. is it using oil?

    Stuck vanes by themselves do NOT necessarily require a rebuild/replacement turbo.
    You have many cheaper options, depending on your mech ability.
    1.I have found you can easily check for full vane movement by using a long screwdriver or similar over the back of the engine and press firmly on the actuator lever between the intake and outlet compressor wheels, until it reaches a hard stop.Doing this a few times may even be enough to free up the mechanism.
    2.You can chemically clean the vanes.I have done this on mine with no ill effects, with Mr Muscle oven cleaner.You have to remove the exhaust outlet pipe though.You can also check for bearing movement
    See here,
    Chemical cleaning for turbo vs removal? - TDIClub Forums
    3.Don't drive a variable-vane turbo diesel like a granny.Give it an Italian tune up once a week or so.
    Last edited by Rebuild; 12-01-2014 at 07:13 PM.
    Steve
    04 T5

  4. #4
    Join Date
    Oct 2008
    Location
    Mt Cotton
    Posts
    3,756
    Our T5 also showed the same symptons for many years as ours tended to hesitate when I turned into our street as it went up very steep immediately after turning . Now turning it off and on would clear it but to be honest I used to think it was the auto that was the problem as the internal filter was gradually blocking along with fluid decay as well . When the auto finally failed and was rebuilt it stopped happening , coincidence I am not sure . But the dealer who did repair the aircon bearing and also did a major service along with an auto trans service at the time told me that the Turbo was leaking oil and very casually told me if I wanted that fixed it would be an extra $6000 !! It is still going strong now 20.000 kays along from then so who knows . I know the whole engine trans and turbo are intertwined through the computer so how do you sort it out . My esteemed friends on here will for sure have some logical answers which may help .

  5. #5
    Join Date
    Dec 2011
    Location
    McGraths Hill
    Posts
    22
    Have your codes checked, sounds like a boost pressure not reached situation, you probably have a boost pressure leak and the ecu is going in to failsafe when boost pressure is not reached when commanded.Don't jump to conclusions, have it diagnosed properly.

  6. #6
    Join Date
    Aug 2010
    Location
    sydney nsw
    Posts
    117
    turbo failure is common enough for vw techs to diagnose over the phone. done mine at 150k. had same symptoms you described. in hindsight though i would go for genuine from vw. not from a local garret supplier.
    as others here have said, there are other explanations for the symptoms though, so get the codes read.
    stuck vanes, theoretically, can be cleaned up. whether its worth it or not is another issue. my bearing was well worn at 150k, meaning it wouldnt have done much more even if i did clean up the vanes.

  7. #7
    Join Date
    Jun 2013
    Location
    Newcastle NSW
    Posts
    10
    Thread Starter
    Thanks for the replies.
    Yes Rebuild my vehicle is using oil and the fuel economy has also decreased over last few tanks. It normally gets around 700km per tank (70 - 71 litres) Now lucky to get 600km per tank.
    Anyway off to mechanic tomorrow so fingers crossed that its not too bad.

    Thanks
    Paul

  8. #8
    Join Date
    Feb 2008
    Location
    Adelaide,Oz
    Posts
    374
    I am not a mechanic, just my 2C...
    If it is using oil, it may be the turbo bearings/seals are toast.
    Fuel economy may point to bad/failing MAF IMO
    As above get codes read, it may give some clues

    Also, as per my above link, a blocked intake may also give this Limp Mode condition
    You can easily remove the intake pipe from the EGR/shutoff valve to see this,
    Mine around 130K(it's all clean now, and EGR blocked)
    T5 turbo replacement-asvalveandegrat126k800x600-jpg
    Last edited by Rebuild; 13-01-2014 at 02:38 PM.
    Steve
    04 T5

  9. #9
    Join Date
    Jun 2013
    Location
    Newcastle NSW
    Posts
    10
    Thread Starter
    Thanks Steve, that intake pipe is filthy, I'm not game to take mine off cause it's probably worse but I guess I should. My veh went to mechanic on Tues and was there mainly for a 180,00km service. I told the mechanic about the turbo noise etc. He did the service plus rear brake rotors and pads. He told me there was a code came up for overboost and heard the squeaking noise and he reckons it's just an exhaust manifold leak that is causing the problems and he wasn't concerned saying everything else was fine. He told me that it would probably go better because he had cleared all the codes which he said there was quite a lot. So far it seems to be going better and hasn't gone into limp mode yet so fingers crossed.
    The next thing will be to replace the exhaust manifold which is probably similar cost to replacing a turbo anyway.
    Nearly forgot, incase anybody is interested, the service with the rear brakes replace cost me around $1200 which was cheaper than I was expecting after reading in another thread that a dealer quoted $2500 for a 180,000km service.

    Paul.

  10. #10
    Join Date
    Jun 2007
    Location
    Melb.
    Posts
    823

    That was probably me. Did your mechanic change the gates couplings? This is the part replacement that takes a long time.

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