You got a water leak?

No water leak. These motors have been going at 30-40K. Mine went at 130K with Mobil 1 oil changes every 5K rural highway driving only. People racing these motors have noticed this as well. Seems to be a basic design problem with motor. VW NA refuses to pay most warrently claims on these motors. I am looking for a lube engineer that may be familiar with this problem. Some Mazda motors and Toyota non turbo motors had a similar problem. Both Mazda and Toyota replaced motors regardless of mileage.

Sludge is not a 'design problem', water in the oil is.

At some point or time, moisture is combining with your oil and the sludge is settling out.  Heavy stop and go that never allows the oil to heat up and/or overly long service intervals have been the underlying cause in almost every car that I have seen a 'sludge' problem.  I'm not saying your problem is not 'unique' but, if it were my problem, I would take a serious look at mechanical conditions and a close scrutiny of the service intervals.

Rod

>"Some Mazda motors and Toyota non turbo motors had a similar problem. Both Mazda and Toyota replaced motors regardless of mileage."<

I'm surprised that Toyota would give anything away.  So many Supras have blown head gaskets because of design problems and Toy. won't do anything.

I think what is happening is that these motors are running at higher than normal temps with the turbo through the oil passages. The oil passages build up with sludge which restricts the flow even further and even more heat builds up. The fine screen on the oil pump pickup also clogs further restricting flow.

How hot does your water temp. run?  How often did you change the oil and filter?  Synthetic?  4 qts. is a fairly good amount of oil for a 1.8 engine.  Where are you driving?

I do not know what the water temp was. I was thinking that turbo motors run a little hotter than non turbo. Synthetic Mobil 1 every 5,000 miles. 95% was rural Highway driving constant speed 65 mph, 6 to 5 hours at a shot. This is a very common problem with these motors in the Passat and Audi A4. Most of them blow at 35,000-50,000 miles in suburban driving. There was never any chocolate milk look to the oil that would indicate coolant in the oil. More of a very dirt look like soot was mixed with it. There were lots of large carbon type deposites on the valve cover.

are you using a synthetic oil formulated for a diesel?

No I was using Mobil 1 for gasoline engines. The 1.8 T is a gasoline engine. What I think was happening was that the turbo oil channels were "cooking" the oil causing the carbon deposites.

In my experience Mobil 1 after only 5000 miles should still look nearly new.  I strongly suspect there is water involved with your problem.  What have you learned from Passat car forums?

Not much VW has been replacing some motors but not others. I understand this is a widespread problem and if VW did a recall it would bankrupt VW NA. I have filed a complaint with the NTSB on this for a recall. I am going to ask some Audi race guys about this problem. I knw it is a problem with the Audi A4.

FWIW, I think the NTSB only requires recalls on safety-related defects.  Now for the past several years they have defined some engine shut-downs as a safety hazard and required recalls, but unless there are a lot of Passats that are siezing on the highway I wouldn't expect much relief from them.  They are not in the business of enforcing warranties, only improving highway safety.

Are you hoping that VW will cut you a deal on fixing your car, or just curious about the root cause of your engine failure?

There are a lot of these motors seizing. I also have good friends at the top of NTSB and some political muscle. VW will not cut a deal. I am in the process of filing a law suite against VW.

I am curious to the cause as well as I have never seen deposites like this in motor before. I have taken apart a lot of motors. I as a car freak I have restored  a couple of Alfa Romeo's, Ferrari, OSCA and Lotus cars.

Well, I hope you end up with an equitable solution to this.
I have seen a thick goo similar to sludge in an engine that was subject to a serious and long term overheated condition where the engine finally expired...never in a 'normally' operated engine--- operated within design parameters.
  
Keep us posted as to your findings.

Rod

Mrpbody44,

Have you ever been to www.vwvortex.com? Lot's of VW info there.

I picked this up in "The Car Lounge" on that sight.

[QUOTE=tjl]

VW's oil change specs recently are:

2.0L, TDI, VR6:  10,000 miles
1.8T, V6 (Passat):  5,000 miles

Variable oil change intervals are not a factory option in the US.

Where VW erred was not giving a tight enough oil specification.  For years, they said something like "use 5W-40, but you can use 5W-30 if 5W-40 is not available".  So lots of owners and dealers put in 5W-30 conventional oil instead of 5W-40 oil (which requires at least a group III based oil, which is labeled as "synthetic" in the US).  In 1.8T engines, that can result in sludge.

VW now recommends VW 502.00 rated oil in 1998 and newer gasoline engines in the US.  All such oils in the US are group III or IV based ("synthetic").[/QUOTE]