2005 VW Passat 2L TDI - Low Power - Black Smoke - P0299 Turbocharger Underboost - Easy fix!

2005 Volkswagen Passat 2L diesel came in the shop with a complaint of no power and blowing a LOT of black smoke. Easy to tell that the turbo is not making boost but it didn't sound or feel like a typical boost hose that's blown off.
@myturbodieseldotcom made an excellent video about these turbos. He disassembled one to show all the components, including the variable vanes, and talked about common problems.
• How a TDI engine VNT t...
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[@23hublock1]

Yep had this elbow hose go on my 2004 1.9 TDi Passat. It took about a year to find the fault and 4 technicians. That was about 14 years ago now, still got the car and replaced that hose still fine to this day....and yes was expensive!! Mine split on the other side of the elbow so the mist oil patch was hidden away and not obvious. UK viewer, liked :)

[@Garibaldiortiz]

Ur a champ!! This is literally what i think is wrong w my ride!

[@timdupont3227]

I just had the lower hose go on my 2004 Passat. The one between the turbo and intercooler. Apparently it must be a solid gold and titanium hose as it was $450 Canadian Pesos. Let's hope I don't need to pay someone to install it once it arrives in a day or two.

[@100Ronster]

Good to know, wow $300.

[@eurbanautotech]

@Dave Ya, it's a diesel thing... On the Chevy Duramax they have small flexible couplers between the intercooler and metal boost pipes. They're held on by large gear clamps. You have to remove them to gain access for a lot of things. They're not like regular coolant hose clamps. One side has a large stud that goes through the other side and you tighten down a nut to get it to clamp. I learned early on to run a chaser over the exposed section of stud before trying to back that nut off! Otherwise the nut will jam up on dirt/corrosion and damage the clamp. Just spraying Moovit isn't enough... You'd think you could get those clamps by themselves but no... None of our suppliers carry them. Including the dealership. You gotta buy the whole coupler piece just to replace the clamps. That's a $300 hit just for an aftermarket one! You can get aftermarket boost clamps for these but they're junk.

[@connorewers478]

45bucks on part geek 100 through autozone

[@eurbanautotech]

@connorewers478 Correct. If it's your own vehicle then you can usually save a lot of money ordering parts online. For automotive shops this becomes more complicated. Ordering a part online can take a week or two to arrive (I'm in Canada), they're lower quality, sometimes have fitment issues, major headache to get warranty on faulty parts, if it's a wrong part (happens all the time in this industry), then you have to send it back and wait another week or two for the correct part to show. All this adds up to turning a job into a loss. As in the shop having less money than if they never took on the job in the first place.
The reason why shops don't want to install customer supplied parts is not because they're "greedy". It's because the shop is a business that has expenses. If you don't manage those expenses your doors close and you go out of business. Part of doing business is warrantying your work even when it is no fault of your own. Such as a faulty part (new doesn't always mean good). When you warranty a job you get nothing for labor. Bills become harder to pay. Add to that the cost of waiting for a replacement part and possibly having a bay tied up or spending the time to put things back together just to pull it back apart again when the right (hopefully) part shows up. These are the factors that go into why shops don't like Autozone/Parts Geek/Rock Auto/eBay/etc.