transporter shuttle 2.5 tdi LWB 2005

**ducassos** · 29-01-2015,12:11 AM

Hi, I am after a bit of advice. I am no mechanic so please use simple terms I can understand

. I have had my shuttle since 6months old and 1000 miles on the clock. It now has 54,000 mainly motorway miles of 2 to 300 miles round trips. At about 25 - 30000 miles started to get limp mode at just over seventy about 2,200 revs. I have have to endure long trips keeping to seventy. If I overtook a lorry at 65 I had to do it very gradually not to exceed seventy or accelerate to much or it would cut into limp mode. My friend is a vw mechanic and says he will take off the turbo and de-gunk it as the variable vanes are probably stuck up. When this is taken off does the manifold need to come off as well? Only when I start up I get a slight smell of exhaust fumes in the cab. I have seen these crack on the welds, could this be part of the problem and can they be welded or will it need new? When diagnosed it says turbo over boost. Also starting to get a squeal as I change up through the gears. Hope its not a new/recon turbo.

thanks in advance

**Sam** · 29-01-2015,09:44 AM

Welcome to VWAF

Has you friend who is a mechanic scanned for fault codes? What did he find when he did?

**ducassos** · 29-01-2015,11:21 PM

Hi thanks for reply, all that shows up is overboost. today he took off turbo. its slightly gunked up on exhaust side. but bolts were solid and some snapped in casing. which are easy enough to extract but 2 bolts holding the variable vane ring snapped as well. They need to send it to engineers to extract them. the turbo spindle etc looks fine ,no slack etc.
another problem tha will cost is the ***** vw manifold. 2 cracks behind welds. seen a manifold on ebay for 279 . made of tough cast iron. 2yr warranty . they say high crack resistant?? not like vw steel ones? check it out see what you think. cheers.

http://www.ebay.co.uk/itm/NEW-EXHAUS...item2c7da805ac

**Sam** · 30-01-2015,10:45 AM

Whilst I'm quite happy to spend someone else's money, it would be nice to have the codes - "all that shows up is overboost" isn't a code(!) - just to see if any of our resident nerds can offer you some advice before you go purchasing half of eBay

**ducassos** · 30-01-2015,03:26 PM

cant remember what code came up. but turbo studs are being removed hopefully so wont need to spend out on recon.
just cant make up my mind for the manifold. cast one is 279 or vw same as at 405. whether cast would be stonger?mqxftVKGpfvTmR6eOTEP2_g.jpg
Has anybody ever welded the cracks around the welds on these to any success?

**ducassos** · 10-02-2015,05:40 PM

shuttle 2.5 tdi steel vw exhaust manifolds are absolutely useless and badly manufactured. Vw deny there is a problem.
new these are £450 for what. They are not fit for purpose. Vw need to admit this and do something about it.
had this shuttle from new(6months 0ld 1000 miles) started to go into limp mode around 25,000 miles. All fractures are on the welds.
started going to limp mode at about 25000 miles .DSC_0007.jpg DSC_0005.jpg DSC_0002.jpg DSC_0004.jpg

**ducassos** · 18-03-2019,07:22 PM

sorry for very late reply, moved house among other things , my old problem of limp mode was caused by cracked welds on exhaust manifold where it comes out of head ports. put on cast iron manifold , hell of a lot cheaper.
have a new problem now . don't know if there is any revalence to this but I pulled out of a junction into busy traffic. wheels spun and jumped , got about 1 km down the road and over heating warning light came on and gauge shot up .AA came out , no engine problem gauge showed normal 90 deg but coolant wasn't hot? No losss of coolant. AA man said he suspected thermostat or water pump . He said they have problem with the vanes (plastic?) braking off , so pump still spinning but not pumping coolant round,? When idling gauge was on normal but soon as drove off gauge shot up.

btw I posted on this old thread because I can't see a post button to post new??

**ducassos** · 19-03-2019,05:47 PM

only codes AA man found were these which i think are irrelavent!DSC_0526.jpg

**Crasher** · 19-03-2019,06:22 PM

You need a proper VAG specific diagnostics report carrying out.

**ducassos** · 20-03-2019,01:12 PM

only codes were
03DF INT LIGHT
063E POWER SUPPLY LESS THAN MIN
063EPOWER SUPPLY MAX EXCEEDED
0385 REVERSING LIGHT FAULT (BUT I THINK THIS IS MY REV BLEEPERS INTERMITTANT FAULT)

sorry to be a pain in the A , but I started it up this morning left it idling till the gauge was normal 90 sat there with revs to 2k for 15 mins ,gauge still normal but expansion tank and hoses cool. top hose on rad was warm not hot. NO HOT air coming from heater. took it down the road about 500 meters and gauge started going up. Got back home left it running, gauge went back to normal. hoses still not hot ,expansion bottle starting to get a little warm not hot.