T5 2007 Multivan Highline auto issues.

[JonWil]

My wife purchased a 2007 Multivan Highline auto, 240,000km in January.


So far she's spent $5.5k on repairs on slide doors, and a bunch of other errors. I expect Glen Waverley VW took her for a ride.


Issue 1. (FIXED: exhaust manifold on passenger side loose)
The warning light for the EGR is a problem before and after GW VW 'fixed it'. The warning light stops if the engine is restarted but doesn't have performance issues once restarted. This is worse when the engine is cold and worse still on cold days. I haven't tried reseating the fuses yet.


Issue 2. (FIXED: exhaust manifold on passenger side loose)
Despite all cabin seals being serviceable, diesel emissions are entering the cabin, what are the usual causes besides open doors or windows? Wonder if it's EGR or cabin filter.


Issue 3. (FIXEDish: Araldite doesn't hold ABS plastic, resorted to pallet packaging strap sandwiched on both sides and 3 screws holding it together)
The inside LHF door cable mount broke from the door card, I've tried Araldite that set for 24 hours before use but that failed. I'll try Araldite and screws next before replacing the door card to save some dollaridoos.


Issue 4.
Yesterday the fuse seems to have blown for the left sliding door, I'm yet to know which fuse, is it bay C, fuse 11?


Issue 5.
Central lock requires multiple attempts to unlock the LHF door. When the door card is off it seems to work well. I'm not sure if the redundant spring outside the door catch unit or dust is causing resistance. What are the common problems with these?


Issue 6.
The sliding doors, particularly the right auto close is currently having hesitations, does this for weeks then works a few weeks. She had them checked, parts replaced but I suspect it's dirt in the tracks.


Issue 7.
The fan inside of the engine bay is scrubbing on the fan couling, some people have asked what the horrible noise is so it's not a good advertisement for VW. I'm hoping there's a cheap easy way to fix this that doesn't cause vibration?


Issue 8.
She purchased a stereo, reverse and dash cam but no fascia plate, is there someone around Melbourne east that doesn't change like a wounded bull to supply the plate and install those?


Issue 9.
Due to the smell of the owners manual, I was hoping to get a digital copy but could only find one regarding air conditioning, are these manuals available online and where would they be?

[JonWil]

In the title, it's an auto transmission but that doesn't have any issues!

[asto]

Sorry to hear about the problems, I’ve been dealing with an 08 high line multivan this past year, theirs a bit of a learning curve with certain issues unfortunately

With issue 2
My van was getting diesels smells inside when sitting at lights and idling, when I had the water pump done they found the exhaust manifold leaking so that was ground flat and refitted with new gaskets (sorted the smell)

And Issue 4
My RHS drivers door would intermittently not lock or unlock and set the alarm off which was annoying, I replaced the whole locking mechanism in the door, about $90 from a wreckers I think
required a torx set and loosely following a YouTube video for a transporter (slightly different) overall not too hard worst bit was removing the trim

As for sliding doors sometimes mine think must encounter too much resistance and return back, just keep tracks clean etc and maybe even use them on manual mode if it’s causing too much of a headache


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[asto]

In the title, it's an auto transmission but that doesn't have any issues!

I thought the auto had issues too! That’s exactly what I’m having fixed on mine ha


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[JonWil]

My condolences!

[JonWil]

If the manifold was loose then the emissions sensor would induce mixture compensation affecting issues 1 and 2.

The door slide tracks seems fairly common as there's a few YouTube vids on the topic. I suspect the extra resistance caused the fuse to blow.

[Rebuild]

2.The usual cause AFAIK, for fumes, is a cracked or leaking exhaust manifold. You can look for soot near the manifold, towards the driver side is most likely.

5.Had this problem too, once it wouldn't unlock at all and i took it to VW, who got it unlocked, "all fixed" they said. Two months later it did it again.
If you can't open the passenger door, you can't fill it with fuel.
Resorted to my own fix
How to remove Door Lock and Assembly Carrier - The Brick-yard

There's also this, with some more info.
T5 driver & passenger door dissassembly instructions

You can find most anything by using the search option on here.

Passenger side has been fine now for, let's see,....8 years.
Drivers side did same about a year ago, same fix, no probs since.

[JonWil]

Workshop manual:
VW T5 Interior fuses 2003 - 2010 | Manualzz

[Silver Caravelle]

Re issue 2 it is not always a cracked or leaking manifold. In fact before heading down that path a free fix is to ensure the exhaust down pipe flange where it meets the turbo outlet is tight. It can loosened over time. Check/tighten with appropriate allen key spanner when cold. A little awkward to get the hand down there with the spanner. Good luck. Regards, Scott

[JonWil]

Thanks Scott, I was going to look around for leaks first before doing anything. The issues are somewhat intermittent so a seal above the oxygen sensor is my expectation. I still have trade tools except for the torx set.

[Silver Caravelle]

No worries Jon. I think it is a reasonably standard size Allen key for the flange clap and not a torx. You mention intermittent smell, it may align when DPF ( Particulate filter) is regenerating say about every 500ks. A bit of a smell in the cabin when this happens occasion when idling at stand still. Not ideal though!

[JonWil]

You mention intermittent smell, it may align when DPF ( Particulate filter) is regenerating say about every 500ks. A bit of a smell in the cabin when this happens occasion when idling at stand still. Not ideal though!

It's becoming almost constant, reversing is worse, not so bad when standing behind with the engine running.

[JonWil]

Looking at the fuses, I've used the list on the T5 ESSENTIALS and added my installed fuse ratings and VIN in this google sheet:
VW T5 2007 Multivan Highline - Google Sheets

or a screenshot of the shortened list of fuses:
https://drive.google.com/file/d/1x_v...ew?usp=sharing

Workshop manual:
VW T5 Interior fuses 2003 - 2010 | Manualzz

Based on the years of manufacture in the Workshop manual on Manualzz, it's going to take me a little longer to decipher these variations.

Compliance plate date: 01/2007

[Kombi]

I had a 08 Multivan with intermittent but also regular exhaust fume smell, i live in the country, almost always there would be no smell on the open road but regularly smelled at traffic lights or intersections, so that would likely rule out dpf burn cycle, I did fix an oil leak on turbo @nd a cracked egr pipe, anyway about two years ago sold the 08 and bought a 12 Multivan, shocked to discover new van with same smell ! 12 Van smell disappeared after I cleaned the dpf, not sure if it was the dpf itself causing the smell because when I removed exhaust pipe to clean the dpf I found the clamp not tight very tight on exhaust pipe, in hindsight I should have tried cle@ning dpf on 08 van, good luck

[Silver Caravelle]

My experience is a very slightly loose top clamp at the top of the turbo to DPF is generally the culprit as previously mentioned. The almost constant smell when at the lights went away ( less likely to pick up smell at speed as it is blowing behind) when checked/tightened further. But it is worth checking/tightening the lower DPF to exhaust clamp as well as other exhaust clamps. The DPF clamps should be semi regularly checked for tension in my view.