Exhaust Fumes in Cabin - Suspected Leak at Turbo - T5 AXB 2004

[Wilkywilk]

Hello all,

Long time follower, first post.

I purchased a 2004 Volkswagen Transporter T5 3 weeks ago,and noticed in the first week that I was getting headaches and feeling unusually dopey/drowsy after driving it.

Engine and Turbo Info:
-Turbo number: bv39A-0020 / 038253014h
-Engine: AXB 1.9 TDi – Transporter T5 2004

I believe I have a leaking turbo where the VNT actuator shaft enters the exhaust side of the turbo housing – the below details the evidence I have gathered of that being the issue. Did the soapy water test initially on the exhaust manifold,as I read on this forum that that part is often the culprit. All good on that end.Then I delved further into the belly of the beast, luckily I have long skinny arms, and was able to spray the soapy water on everything related to the exhaust.

Photos below.

1.Vacuum actuator hooked in to VNT actuator lever, photo taken from top side, bubbles seen on startup.




2.Zoomed in photo of actuator arm as it connects to VNT actuator shaft, from top side.





3.Taken from underneath, VNT actuator lever, telltaletraces of soot indicating leak.






4.Zoomed out photo from underneath, for perspective,of actuator shaft. Noted this area of the turbo is quite rusty compared to theother parts.





5.Youtube link to video of soapy water test.
https://www.youtube.com/watch?v=Unt6PSqcdpQ&feature=share




Volkswagen, being Volkswagen, do not provide an assemblydrawing, and they will only sell the turbo and exhaust manifold as a singlepart. If you don’t use VW dealer who want 4k for supply only on this assembly, then you must work it out yourself. Thus, due to the wearing of what I assume to be a single brass bushing, I am getting exhaust fumes in the cabin, which may end in a 1.4k part cost from an OEM. Assume total will be around 2k including install, if I don’t do it myself. I am very keen not to incur this cost, as I just bought the thing for 10k. The way I see it, based on solutions I’ve seen for other vehicles, there are three options:

-Remove the turbo and exhaust manifold, reverseengineer the bushing I assume will be in there - $50 and a lot of time. Of courseobtaining a part number or assembly drawing would make this a little easier.

-Purchase a new or reco turbo and exhaustmanifold, replace. $1400 and slightly less time than the above

-Weld the actuator arm in some sort of intermediate position and see what happens. I have read and seen on youtube that people have opted for this. Doesn’t seem particularly wise. I am unclear on the implicationsof this on the vehicle’s operation (assume there will be some implications for the vehicle’s life in this option too).

- Also, service the bushing somehow? If it wasn’t a rotating component it would be a job for exhaust cement. I know if you ruin a thread you can repair it. I wonder if there is an equivalent for a shaft and bushing. Scraping the bottom of the barrel here.

Long time observer of this community, and appreciate the excellent advice that I have received as an observer over the years. I would very much appreciate any comments or pointers anyone could give.

Regards,
Chris

P.s. apologies if there are any words or off-fonts. Took a while to write and when I finally posted it the formatting went wild.