T5 2.5 TDI 174 - My first California?

[tvagon]

Then a small report about yesterdays test drive:

Besides the drive I tried to go through all the functions and features. Would have been great to check things @Benny mentioned, but had no clue about those.

At some point while driving I got a sens of exhaust gas, but couldn't be 100% sure since it was really mild.
Have to say, ride was smooth and comfy and motor was not giving any hints to doubt it's condition. Tires unerd were 235/65/16r winter. Summer tires were in the latter side of their life cycle.

Despite the list below, I found everything working.
-I went through the latest service reports and it said that exhaust manifold is in need of change (just what @2into1 said) So that is going to hurt me 600+ euros?
-Also, when checking under the vehicle I saw a quite rusty exhaust pipe. I guess it is prone to rust due to heat? Anyways, it may need to be changed in some time. (Some UK made stainless steel Scorpion pipes were 400 £ but there may be something cheaper out there?)
-Heater was working (at least I got it on and heating), but I could not get a grasp about its functions since the menu was in German and the display had few dead pixels which complicated reading a little.
-Kitchens big light was not working.
-Drivers headrest affected to be jammed.
-Minor rust (few millimeters) patch was under sliding doors sliding slot on the rear side.

I know those thing are not major, just wanted to be as precise as possible.
And sorry, forgot to take pictures.

 

[steve_b]

The kitchen big light is a mini-fluorescent tube and takes a few second to come on, if you don't know that, it is very easy to think that it's not working and turn it off again.

Re the rusty exhaust, I believe they are twin walled, the outer one looks rough as anything but the inner one lasts a lot longer that you would imagine by looking at the outer - however nothing lasts forever

 

[tvagon]

Oh I see. I most likely switched it off immediately since I thought it was not going to turn on. Thanks!

And yes, it very much seemed like twin walled, since the outer layer was already partly off.

 

[Benny]

Coolant reservoir is front left under the bonnet and will likely have a green cap with a dipstick attached. You can check the oil on the dipstick. Look under the oil filler cap. A little white sludge on the cap is O.K, but I would be worried if you can see "mayo" in the filler neck. There are a few reasons why water gets into the oil and none are cheap to fix. The ac freewheel is underneath at the front of the engine. It is attached to a black disc approx 4" in diameter. You should be able to turn the disc one way. If you can turn it both ways the coupling needs replacing. If you can't turn it then the freewheel has jammed and will need replacing. The ac pump may also need replacing.

They are reliable engines when properly serviced but are absolute money pits when something goes wrong. If you are not mechanically minded then I would advise having a mechanic inspect it with you.

 

[Big Ted]

That was a good read, thanks @Big Ted! Needed support for hard decision. Sounds like it is a good fit for your family. Also double glazed windows sounds like a good thing especially on the northern latitudes. Have to check if this one has them or not. Also, how many miles you have covered and has your rainy day fund seen a lot of use?

We’re now covered 14/15k since we bought the Cali.
In this time we’ve had a service, PAS pump and water pump replaced due to leaks. So a few dents to the rainy day fund, but since it’s a 10 year old vehicle I don’t mind replacing stuff as I intend to keep this one for a good number of years/miles.
I’ve spent a bit of the fund on upgrades with B14’s booked in for fitting after Easter too.

 

[tvagon]

Coolant reservoir is front left under the bonnet and will likely have a green cap with a dipstick attached. You can check the oil on the dipstick. Look under the oil filler cap. A little white sludge on the cap is O.K, but I would be worried if you can see "mayo" in the filler neck. There are a few reasons why water gets into the oil and none are cheap to fix. The ac freewheel is underneath at the front of the engine. It is attached to a black disc approx 4" in diameter. You should be able to turn the disc one way. If you can turn it both ways the coupling needs replacing. If you can't turn it then the freewheel has jammed and will need replacing. The ac pump may also need replacing.

They are reliable engines when properly serviced but are absolute money pits when something goes wrong. If you are not mechanically minded then I would advise having a mechanic inspect it with you.

Thanks a lot @Benny! I definitely need to make one more check. And then, I guess, I'm ready to decide.

 

[2into1]

I think I've finally got rid of my exhaust fumes. I changed the manifold (to a vw one but at a special price). The old one wasn't cracked but may have warped a little. Even then, I still had smells and found leaks on the EGR pipe gaskets (both ends) and then at the joint between the turbo and the dpf, and then between the dpf and the exhaust.
If you go ahead, find a mechanic with a special smoke machine. The one I eventually found just pulled off a hose on the inlet side and within minutes we found and dealt with the leaks. I wish I'd started with that machine to hand.
Best of luck.

 

[Sean Gardiner]

I have a 2004 LHD 2.5 (axd) 130ps California, have done 20k in it in the past 3 years, and loved being with it. Very economical if you stay below 65mph, I've even seen 45mpg creep up on long flat runs, almost as good as my Skoda Spaceback 1.2tsi!
I've avoided tuning it, as I like stock vehicles. Having heard of the higher bhp models experiencing gearbox wear on manual boxes.
My manifold cracked and was filling the cabin with fumes, an expensive job, and the replacement was hard for my garage to fit costing me total £650 (£310 for the manifold). I purchased the manifold from Darkside developments. I think it's a cheap cast iron one painted black to justify the extra cost, but they guarantee it'll fit.
Thing with these older Calis, yes, they will need bits, I've literally just spent the morning diagnosing and replacing a faulty water tank submersible pump as the fuses are not identified and it takes ages to check them all, but i'm not bitter, I love the van, it may even have increased in value since purchasing, and brings so much freedom and joy. Also the build is rock solid, and at 75k miles, the engine purrs still.
Good luck with your purchase and, of course, it's worth every penny, and the price depends on supply and demand. Custom build newer vans come nowhere close to the quality integrated feel. Don't take my word for it, stop any cali driver and ask them.
Good luck, Sean

 

[2into1]

I've even seen 45mpg creep up on long flat runs

I should add to those making comparisons with different models, the mpg figure in my 2006 Cali is VERY accurate (so I suspect Sean's is too), unlike the T6, where 40mpg on the computer was 36mg measured properly.

 

[Crasher]

I think I've finally got rid of my exhaust fumes. I changed the manifold (to a vw one but at a special price). The old one wasn't cracked but may have warped a little. Even then, I still had smells and found leaks on the EGR pipe gaskets (both ends) and then at the joint between the turbo and the dpf, and then between the dpf and the exhaust.
If you go ahead, find a mechanic with a special smoke machine. The one I eventually found just pulled off a hose on the inlet side and within minutes we found and dealt with the leaks. I wish I'd started with that machine to hand.
Best of luck.

Hi 2into1
I am also having fumes in cab .Can't find any soot or any noise or blowing from gaskets.Where was the mechanic you used and where did you source the cheap manifold as I may need one 2.Cheers

 

[steve_b]

I had fumes in the cab, it was actually an oil smell not exhaust fumes . Apparently there is an oil breather in or by the air filter box , if that is blocked or blows back it puts oil into the air filter and an obvious smell in the cabin. Pretty quick and easy to check

 

[2into1]

Hi 2into1
I am also having fumes in cab .Can't find any soot or any noise or blowing from gaskets.Where was the mechanic you used and where did you source the cheap manifold as I may need one 2.Cheers

I found the manifold on ebay as new old stock and darkside developments fitted it. The guy who did the further detective work was Fairway motors in Glossop. I think @steve_b s post is important. I'm not sure I've 100% sorted mine so I'll be looking at his tips too. It would certainly be a cheaper place to start!

 

[2into1]

I had fumes in the cab, it was actually an oil smell not exhaust fumes . Apparently there is an oil breather in or by the air filter box , if that is blocked or blows back it puts oil into the air filter and an obvious smell in the cabin. Pretty quick and easy to check

Steve. Can we hash this out a bit, based on my rudimentary knowledge ? It sounds encouraging but I'm not sure how crankcase (?) fumes and oil getting into the combustion process would result in smell in the cab. My logic says that it must be "smells" (exhaust gas, oil mist etc) from the engine bay getting blown through the ventilation system into the cab. Is it that the blockage you describe means that "smells" FAIL to get back into the combustion cycle as intended (because of the blockage) and therefore exit into the engine bay and into the cab?

 

[steve_b]

I don't really know, I sent it to my mechanic and I can only relay what he told me. As I understand it, oil was being blown out of the engine into the air filter housing and on the air filter. Note this is the air filter for the cabin air (pollen filter) so filters air intended for the inside.

 

[Crasher]

I found the manifold on ebay as new old stock and darkside developments fitted it. The guy who did the further detective work was Fairway motors in Glossop. I think @steve_b s post is important. I'm not sure I've 100% sorted mine so I'll be looking at his tips too. It would certainly be a cheaper place to start!

Thanks for responses .
Booked in with an independent on Wednesday in Leeds.Darkside couldn't fit me in until mid February and was going away.Hope they sort the problem.Will relay what you guys have said.Cheers .Could you see any soot? 2 into 1 or hear any noises.I also get a noise around 1800rpm to 2500 rpm .Only had 16 month .love the bus done loads of fixes leaky windows gates couplings etc this is above my pay grade.

 

[2into1]

Thanks for responses .
Booked in with an independent on Wednesday in Leeds.Darkside couldn't fit me in until mid February and was going away.Hope they sort the problem.Will relay what you guys have said.Cheers .Could you see any soot? 2 into 1 or hear any noises.I also get a noise around 1800rpm to 2500 rpm .Only had 16 month .love the bus done loads of fixes leaky windows gates couplings etc this is above my pay grade.

Had a bit if soot on egr pipe. Exhaust manifold is very difficult to see before dismantling gets underway. Fingers crossed for you.

 

[Crasher]

Had a bit if soot on egr pipe. Exhaust manifold is very difficult to see before dismantling gets underway. Fingers crossed for you.

Hi been to independent vw specialist today nice chap.Said he had smoke tested and no sign off a leak .Advised to extend coolant heater away from engine and see if improvement made.Then he said would have to start stripping things. concerns are may replace manifold and be same .

 

[2into1]

Hi been to independent vw specialist today nice chap.Said he had smoke tested and no sign off a leak .Advised to extend coolant heater away from engine and see if improvement made.Then he said would have to start stripping things. concerns are may replace manifold and be same .

I share your concern as it's a big expensive job. If its not killing you, you can keep driving and gathering data (weather, temperature, engine temp etc) to provide more clues.

 

[Crasher]

I share your concern as it's a big expensive job. If its not killing you, you can keep driving and gathering data (weather, temperature, engine temp etc) to provide more clues.

This is another chaps experience. Interesting his was diagnosed as manifold then when stripping discovered egr pipe.Also making a noise like mine at 1800 to 2000 rpm.Never finished thread so have messaged him .Waiting his response.