Returning Owner - Help with the latest issues

Lost Boy · Friday at 10:11 AM

After owning a 5.1 Berghaus for 3 years back in 2014-2017 ish, i am potentially back in the market for a 6.1 Ocean, hopefully a 204. I wondered if I get get some help with an update on the latest known issues, I recall it was roof corrosion, EGR failures back then, I am hoping all of that is resolved by now. i have picked up on FB that there appear to be some issues with the waterproofing of the canvas but was wondering if there is anything else i should be on the lookout for??

Thanks in advance

lohr500 · Friday at 10:52 AM

If you are looking at a recent 204, then I think the main thing to check is the roof bellows.

Unless the Cali you are looking has the latest 06S version of the bellows fitted, then they could leak.

I'm not sure when the design change was made from the bellows with the darker coloured inside, to those with a light coloured interior, but my understanding is that the main leakage issues started with that design change. (Hopefully someone can confirm this)

If any van you are viewing has the lighter coloured internal material, then it is easy enough to spot if the latest 06S bellows have been fitted. The vertical side seams will be taped with a clear waterproofing tape.

Here is a photo I copied from another post, showing the taped seam.

Previous reports suggested that not all of the pre 06S version bellows leaked, but for many of us, they did.

Options to resolve the leaks are to either spray with Aquatex (VW would not give a definitive "OK" to do this without invalidating the warranty) or to seek a warranty replacement.

I went down the Aquatex route with my 04S bellows as at the time I wasn't convinced a warranty replacement would be any better. The Aquatex worked perfectly and our Cali has been leak free since April last year.

Given the positive reports on the latest 06S version, I think I would now be pushing for a warranty replacement if I had any further leaks, or if I purchased a van that had a leaking roof.

Lost Boy · Friday at 10:56 AM

Brilliant thanks, no engine or roof corrosion issues with the 6 or 6.1?

Perfectos · Saturday at 11:30 AM

Lost Boy said:
Brilliant thanks, no engine or roof corrosion issues with the 6 or 6.1?

Both issues persist:

All Cali roofs since inception are Aluminium and therefore have the potential for bimetallic corrosion under the right conditions, the issue with the T5/ 5.1 front "cap rot" affecting the fixed roof section seems to have been substantially resolved from T6 onwards, although their are some reported issues with failures allowing water ingress. (water ingress due to failed seals around the sensors),

The roof seal is the same as it always has been, steel reinforcements covered with a woefully thin rubber coating, VW are acutely aware of this issue and have decided to do very little to resolve the issue:
Roof perimeter seals are know to have been faulty from new. (All California models from T5 to present).
The seal has the potential to cause roof corrosion where it meets the roof. in a cynical attempt to delay this VW fitted clear tape to three edges of the roof (sides and rear), applied to T6 onwards , early T6 was subject to service recalls to retrospectively fit the tape at dealers. The tape merely delays the issues caused by faulty roof seals, the front section (of the raising roof ) is not tapped and remains unprotected! DYOR.

Issues with EGRs still exist, there is evidence that the 180 - , 199, 204 Biturbo models can still suffer from premature engine wear. (More reported on T6 forum than here. ) although various factors seems to have a role to play in the premature wear from failed / corroded EGRs.
VW do not admit the issue exists which leaves those affected with hefty Bill to replace engines and swap out ancillaries etc.
It seems single turbo models have escaped the widely report issue. DYOR

The Cali , in its various guises remains a great Vehicle.