Tale of woe

Tourershine

Senior Citizen.
VIP Member
T6 Master
A couple of people asked recently why I seemed to have gone quiet lately. Well, I haven't actually gone quiet, I've just had a catalogue of issues with my T6 recently, which sadly still aren't quite resolved.

This all started with a cracked exhaust manifold, which we removed and went to order a new one, only to be told that you cannot actually buy a T6 exhaust manifold, unless you purchase the whole turbo (or 2 turbos in my case, because it's bi-turbo) to top the eye watering price of a new pair of turbo's, VW couldn't give me an actual delivery date and quoted 6-12 weeks, which obviously didn't work for me because the van is in daily use for my business. So, we brass welded the manifold in the hope it would seal the crack and flex with the heat of the manifold.
Yes, the weld worked, but it didn't fix the issue, because we still had fumes in the cab and Black smoke upon revving from the manifold area (more cracks)
Anyway, we decided that we didn't want to loose the van for two more days whilst we took the turbo off again, and just put up with the unfiltered fumes, mitigating by using the internal recirculating button to block air from entering the cab. Job done for now.

This all seemed to work for a short time and I could get on with work, but several weeks later on a very hot day, I noticed a weird noise on the way home from a job in Norfolk. This noise then developed into the van not feeling right. It seemed to lack power on initial pull off, which only got worse, the closer we got to home, until 'boom' a pop, followed by a loud knocking noise, shortly followed by a plume of Blue smoke and then the engine management light, then stop. Yep, a blown turbo.

Long story short, we got the van towed to my garage and got the new turbos and yesterday we fitted the new turbos in the hope that this was all the answers to the T6 prayers, but alas, not so.
This is where the fun has started and pretty much where we are now. Firstly, the van started fine, no smoke and no lights on the dash, but we noted that nothing was exiting the exhaust, and by nothing, I mean zilch. No smoke or even air. Quickly switched off, we determined the DPF was blocked solid, so removal and a dash across Leicester to a very helpful company that specialises in DPF cleaning. After a quick test, they confirmed it was blocked solid and put this down to the turbo throwing oil through the exhaust, thus blocking the DPF. After a couple of hours, they managed to unblock it and a quick test confirmed all ok. Back on the van it went, and again it started, but this time we have exhaust gasses exiting the exhaust. However, it still seems like it's blocked somewhere. There's an obvious hissing from the exhaust as if it's struggling to get the gasses out fast enough and we have an engine light on, indicating it's not happy. My tech road tested it and he said it's not right, and that's pretty much where we left it. Him annoyed it's still on a ramp and me pretty deflated.
 
Sorry for your woes……but it’s great that you post the bad bits about our vans so we can all be informed ..that’s what’s good about this Forum….Sharing good and bad….hope you get it sorted :thumbsup:
 
It sounds like the oil might have blocked the cat or the dpf then?

That would be my first place to start anyway.

I wonder if the dpf was blocked before which contributed to the manifold and turbo failure?
 
A couple of people asked recently why I seemed to have gone quiet lately. Well, I haven't actually gone quiet, I've just had a catalogue of issues with my T6 recently, which sadly still aren't quite resolved.

This all started with a cracked exhaust manifold, which we removed and went to order a new one, only to be told that you cannot actually buy a T6 exhaust manifold, unless you purchase the whole turbo (or 2 turbos in my case, because it's bi-turbo) to top the eye watering price of a new pair of turbo's, VW couldn't give me an actual delivery date and quoted 6-12 weeks, which obviously didn't work for me because the van is in daily use for my business. So, we brass welded the manifold in the hope it would seal the crack and flex with the heat of the manifold.
Yes, the weld worked, but it didn't fix the issue, because we still had fumes in the cab and Black smoke upon revving from the manifold area (more cracks)
Anyway, we decided that we didn't want to loose the van for two more days whilst we took the turbo off again, and just put up with the unfiltered fumes, mitigating by using the internal recirculating button to block air from entering the cab. Job done for now.

This all seemed to work for a short time and I could get on with work, but several weeks later on a very hot day, I noticed a weird noise on the way home from a job in Norfolk. This noise then developed into the van not feeling right. It seemed to lack power on initial pull off, which only got worse, the closer we got to home, until 'boom' a pop, followed by a loud knocking noise, shortly followed by a plume of Blue smoke and then the engine management light, then stop. Yep, a blown turbo.

Long story short, we got the van towed to my garage and got the new turbos and yesterday we fitted the new turbos in the hope that this was all the answers to the T6 prayers, but alas, not so.
This is where the fun has started and pretty much where we are now. Firstly, the van started fine, no smoke and no lights on the dash, but we noted that nothing was exiting the exhaust, and by nothing, I mean zilch. No smoke or even air. Quickly switched off, we determined the DPF was blocked solid, so removal and a dash across Leicester to a very helpful company that specialises in DPF cleaning. After a quick test, they confirmed it was blocked solid and put this down to the turbo throwing oil through the exhaust, thus blocking the DPF. After a couple of hours, they managed to unblock it and a quick test confirmed all ok. Back on the van it went, and again it started, but this time we have exhaust gasses exiting the exhaust. However, it still seems like it's blocked somewhere. There's an obvious hissing from the exhaust as if it's struggling to get the gasses out fast enough and we have an engine light on, indicating it's not happy. My tech road tested it and he said it's not right, and that's pretty much where we left it. Him annoyed it's still on a ramp and me pretty deflated.
Sorry to hear this, what sort of miles yours on now?
 
Ouch, this sounds expensive aswell as annoying , hope you get it sorted soon .
 
It sounds like the oil might have blocked the cat or the dpf then?

That would be my first place to start anyway.

I wonder if the dpf was blocked before which contributed to the manifold and turbo failure?

Its what we discussed earlier.
 
Its what we discussed earlier.
@Tourershine I do hope that fortune shines on you tomorrow and you get your van back on road and earning its keep.

Sounds like your exhaust is blocked. Might be worthwhile taking out the back box and seeing you if you have free flowing exhaust fumes.

Good luck mate.
 
Long shot, but worth asking if any of the technical members can suss out this one, because no one in Leicestershire can! Including a so called 'Transporter' specialist that just took one look and said 'main dealer mate' (who by the way cannot even look at my van until October)

Anyway.

Blocked exhaust sorted, but we have the error below. Basically it runs and drives, but has no power.
The turbo supplier are saying "the car doesn't read the coding from the actuator. Please try to adapt the new part to the car" but 2 separate garages with two different computers, including one that's connected to Volkswagen and both don't give an option to code in the Actuators, only the fault below. I'm booked into another place tomorrow from the recommendation of the tech who fitted the turbo. They are ex VW and have a few different tricks, but I don't hold out much hope.

Any suggestions?

20220729_140422.jpg
 
VCDS translation for P00AF00 - Actuator Module for Turbocharger 1 - Stuck.
Dumb question but surely have verified the actuators move freely? Wastegate? Wiring?

VCDS also suggests that for T6 engines there are four tests for turbos as well as two different adaptations
IDE00457-Test of turbocharger​
IDE00891-Test of charge air pressure control​
IDE07136-Test of wastegate actuator​
IDE07464-Turbocharger recirculating valve test​
IDE00897-Adaptation of the turbocharger​
IDE11075-Adaptation of turbocharger recirc. valve​
 
VCDS translation for P00AF00 - Actuator Module for Turbocharger 1 - Stuck.
Dumb question but surely have verified the actuators move freely? Wastegate? Wiring?

VCDS also suggests that for T6 engines there are four tests for turbos as well as two different adaptations
IDE00457-Test of turbocharger​
IDE00891-Test of charge air pressure control​
IDE07136-Test of wastegate actuator​
IDE07464-Turbocharger recirculating valve test​
IDE00897-Adaptation of the turbocharger​
IDE11075-Adaptation of turbocharger recirc. valve​

We have checked this yes. Along with vacuum pipes etc. I'm convinced it's something daft, but the turbo supplier insists the Actuators need coding to the van, yet no ones diagnostic equipment gives the option to adapt them. Maybe tomorrow might work, but I needed to see if anyone had any obvious ideas because a week of doing this, I'm at the point where I've had enough..

Is it possible to reuse your old actuator?

I thought about this too, but the technician said they are set up when fitted, hence the paint on the threads.
 
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We have checked this yes. Along with vacuum pipes etc. I'm convinced it's something daft, but the turbo supplier insists the Actuators need coding to the van, yet no ones diagnostic equipment gives the option to adapt them. Maybe tomorrow might work, but I needed to see if anyone had any obvious ideas because a week of doing this, I'm at the point where I've had enough..



I thought about this too, but the technician said they are set up when fitted, hence the paint on the threads.
Although they are set up and have the blue bit of paint, did they visually look to be in the same position ? I’m no mechanic but had a similar problem on my crafter when actuator was changed due to a diaphragm split. The guy who fitted it for me adjusted it to the same position as my old 1.
 
Although they are set up and have the blue bit of paint, did they visually look to be in the same position ? I’m no mechanic but had a similar problem on my crafter when actuator was changed due to a diaphragm split. The guy who fitted it for me adjusted it to the same position as my old 1.

To be honest, we were sent a whole new unit with everything bolted to it and they are sold this way with the intention of removing the damaged unit and just bolting on the new one, so other than a visual glance over, we just bolted it on.
 
So.... after tracing backwards the whole job myself on my driveway, I've discovered one of the two actuators isn't holding any vacuum and therefor not moving the arm, hence no boost. So @Matchyt30 you were almost spot on.

The main issue is now the job has to be done all over again because you cannot assess the actuator to change it. I'm really hoping the supplier is going to pick up the tab for having this done again and really hope they will not expect the faulty turbo back before sending a new one out, but it's been one of those weeks.
 
So.... after tracing backwards the whole job myself on my driveway, I've discovered one of the two actuators isn't holding any vacuum and therefor not moving the arm, hence no boost. So @Matchyt30 you were almost spot on.

The main issue is now the job has to be done all over again because you cannot assess the actuator to change it. I'm really hoping the supplier is going to pick up the tab for having this done again and really hope they will not expect the faulty turbo back before sending a new one out, but it's been one of those weeks.
I know it’s not been a great week, but at least making progress and maybe light at the end of the tunnel. Fingers crossed for you.
 
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