common problems version 2.0

oilhammer

Certified Volkswagen Nut & Vendor
Joined
Dec 11, 2001
Location
outside St Louis, MO
TDI
There are just too many to list....
Posting this to consolidate some of the accumulated knowledge here. I got good response from a similar thread a while ago.

The original thread can be viewed here: http://forums.tdiclub.com/showthread.php?t=189029

Going to make this one more streamlined, and broken down by platform. These will be for models sold in North America only. I am just listing the issues themselves without much comment to keep this post easily navigable. Some of the items listed here were in the original post, some are not. Keep in mind the age and typical mileage on some of these cars is creeping up so do not assume your car will exhibit all the problems listed. I see lots of TDIs with over 300k miles on them.

A3 (1997 through early 1999 Jetta, 1Z/AHU engine):

ignition switches, and/or ignition cylinder housing
crank bolt loosening up and damaging sprocket and/or crankshaft
engine and transmission mounts
leaking injection pumps (can be the cause of swollen/blown coolant hoses)
leaking/cracked breather tubes
shifter cables, shifter box bushings, shifter boxes
refrigerant pressure switches
compressors
door harnesses
HVAC control heads
front upper strut mounts
parking brake cables
charge air hoses (at intake manifold mostly)
vacuum/pressure lines (including the one INSIDE the ECU)
N75 valves
cooling fan controllers

B4 (1996 and 1997 Passat, 1Z engine):

everything from above, and...
outer door handles
heater cores
rear calipers (if equipped)
inner CV joints on right side (many B4s did not have a protective cover)
instrument clusters
flexpipe in exhaust downpipe

A4 early (all New Beetles through 2003, late 1999 through 2003 Jetta, late 1999 through 2003 Golf, ALH engine):

01M automatic transmission
injection pumps (clicking)
VNT actuators and sticking VNTs
smashed underbellies
control arm bushings
parking brake cables
fan controllers
radiator fans
compressor clutches
accessory belt idlers and tensioners
vacuum tube to brake boosters
boosters (2002 only for some reason)
oil pump chain (300k+ miles)
long crank time (1998 and 1999 only)
alternator clutch pulleys
dual-mass-flywheel (manual trans)
clogged sunroof drains
wheel bearings (front and rear)
siezed tie rod adjusters
glow plug harness
relay 109 (main engine ECU relay)
condensers (leaks, NB only)
EGR valves
mirror heater elements
reverse lamp switch connector/wires (manual trans only)
brake light switches
leaky vacuum pumps (oil leaks)
coolant temp sensors
side airbag connectors under seats
clocksprings for driver's airbag
fuel temp sensors
power window regulators
saggy front springs
door latches

A4 late (2004+ New Beetle, 2004 to 2006 Golf and Jetta Wagon, 2004 through early 2005 Jetta sedan, BEW engine):

charge air pipe into throttle body
parking brake cables
lift pumps
fuel temp sensors
tandem pumps (leaking)
dual-mass-flywheel (manual trans and New Beetle automatic only)
alternator clutch pulley
camshaft/lifter wear
EGR pipes
EGR coolers
fuel filters (clogging...the PD has no tolerance for this)
glowplugs/software
door latches
air bag connectors under seat

B5 (2004 and 2005 Passat):

A/C 'retarder' relay
outer CV boots
balance shaft/oil pump drive chain (upgradeable)
glowplugs/software
torque convertor (sets TC slippage DTC)
alternator pulley clutch
engine mounts
accessory belts (the larger one splits, the OE Hutchison-branded ones are JUNK!)
charge air hose coming out of the turbo (rubs on ground wire)
EGR coolers

A5 early (late 2005 and 2006 Jetta sedan, BRM engine)

dual-mass-flywheel (both manual and automatic, the auto being worse)
trunk latches
Delphi-supplied radios
door skin bolts coming loose
airbag connectors under seat
rear brake pad wear (may be too tight of parking brake cable)
heater hoses (near turbocharger)
turbo VNT actuator vane sensor (requires new turbo)
fuel temp sensor
camshaft/lifter wear
headlamp assembly connectors
cooling fans
radiators (leaking)
boost pressure sensor (also houses intake air temp sensor)
door wiring harnesses
EGR coolers
rear calipers

A5 late (2009+ Jetta sedan and wagon, Audi A3, CBEA engine):

poor shift quality (automatic)
High Pressure Fuel Pump failure
exhaust temp sensors


...sorry T'reg and Q7 guys, don't have anything for you other than reports of VERY poor tire life.
 
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Growler

Got Soot Vendor
Joined
Nov 24, 2003
Location
Millersport, Ohio
TDI
Schmutz, 2015 Golf Sportwagen DSG & Schnurren, 2001 Golf GL 2 door 5M
Brian,

it would be good if you (or someone) could find a good link to a thread describing each of these issues for more in-depth research.

then you could update your original post with the links as they come in.

the vwvortex does this for its FAQ/HOW TO threads and it seems to work good. (one of few good things about that site)

:)
 

joetdi

Veteran Member
Joined
Mar 8, 2008
Location
Midwest
TDI
2-2002 Jettas W/Auto
A few other problems I have seen with the A5 is broken wires at the door hinges (more the front than the rear) just like the A3. These broken wires have also caused dead batteries due to the can-bus not going to sleep. And alarm problems to.


Seat switches for memory, when door is open water from the roof runs onto the switch causing the seat to move on it's own among other things and this also happens to the power door switches to causing inop.

CEL for crankshaft sensor see the following thread:
http://forums.tdiclub.com/showthread.php?t=239987
 
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honda_vtec2

Veteran Member
Joined
Jul 16, 2008
Location
Toronto
TDI
2000 Golf ALH tdi, 1997 Jetta 1z tdi
Just a few questions:

For the A4, injection pump clicking. What exactly is causing the clicking sound?.

Also, how do you tell if the fuel temp sensor is going bad, and what are the main symptoms.

I have VCDS and can see the sensor temps are within spec.

I'm curious about these 2 items, in case i might have some issue later in the future. I recently modified an ALH pump to fit/work on my mk3.

thanks in advance
 

oilhammer

Certified Volkswagen Nut & Vendor
Joined
Dec 11, 2001
Location
outside St Louis, MO
TDI
There are just too many to list....
Noisy pumps are simply from worn/bad internal parts. Cam plate, shaft, etc. The fuel temp sensor will set a DTC when it goes bad.
 

honda_vtec2

Veteran Member
Joined
Jul 16, 2008
Location
Toronto
TDI
2000 Golf ALH tdi, 1997 Jetta 1z tdi
oilhammer said:
Noisy pumps are simply from worn/bad internal parts. Cam plate, shaft, etc. The fuel temp sensor will set a DTC when it goes bad.
btw: Thanks for the post and sharing your invaluable knowledge. This checklist should be posted in Edmunds consumer reports for previous generation TDI's.
 

That Guy

Veteran Member
Joined
Jan 23, 2009
Location
Edmonton, Alberta, Canada
TDI
2001 MKiv Golf TDI
I've got a few more for ya...for a 2001 A4 Golf.

These first two may or may not be common. But I've seen the rest of the issues mentioned many times in the forums.

Stretched/worn wires to lights in the sunshades.
There's not much slack in those wires. So moving the sunshades around a lot causes the wires to short or break. Located in the hinge part of the shade.

Stretched/worn wires in the hatch.
Same as above...little play in the wires resulting in damage to the wires over time when opening and closing the hatch.
My rear wiper stopped working and the fronts were acting strange.
Location of issue on mine was in the rubber acordian tube on the drivers side of the hatch where it attaches to the main car body.

(I spliced in some extra wire for added slack in both cases.)

Broken lid on the centre armrest.
The only fix seems to be replacement of the whole armrest...about $500 new.

Rust behind front mudflaps.
Due to lack of knowledge of those drains that need to be cleaned in those locations.
And from paint chipped off by mudflaps...after flaps hitting overly large speed bumps.

Coolant migration...down those wires from the coolant tank.
(I drilled the hole to prevent this...but have never had any indication of a leak there myself.)

MAF....replaced mine once

Clogged air intake manifold

Thermostatic Tee issues

Clogged fuel lines...or issue with old revision of fuel sender

Corroded and ineffective grounding wires

Vacuum lines in general...get old and dried

N75?

Clogged snow screen

Those dam door sensors that seem to brake every few years.


....thats's all I can remember off the top of my head. :)
 

bbarbulo

Veteran Member
Joined
Jan 11, 2003
Location
Windsor, ON, Canada
A4: early 2000

rear calipers (seize, strip)
broken ebrake cable housings - leading to corrosion and eventual seizing also
glow plug harness
coolant overflow tank leaking through the connector into the harness
broken hatch wiring (Golf/wagon only)
seized wiper linkage (dr side)
worn seat bolster (around seat airbag in particular)
airbag errors, intermittent ignitor fault in seats
turn signal stalk, wiper stalk (or switches in general)
brake lamp switch
clutch switch
rear trailing arm bushings
front LCA bushings
starter chirping/remaining engaged
rubber coating peeling from interior panels
fender rust
rear hatch handle lock cylinder seizing
rear hatch handle entire casting cracking and bubbling
door switches/alarm issues
steering wheel wears out/shift boot wears out
doors rattle/squeak
broken front spring


those are some of the ones i didn't see in your original list.
 

That Guy

Veteran Member
Joined
Jan 23, 2009
Location
Edmonton, Alberta, Canada
TDI
2001 MKiv Golf TDI
Possibly more common problems for Oilhammer's list....

I had the lock in the hatch go as well....I forgot about that as it was replaced with the hatch....got rear ended a few years back.
The lock was corroded badly. Apparently there's some aluminum parts next to other metals. Simply add water and time. This must be a common issue.
(Thanks for reminding me...gonna lube that up with the marine anti-size...I never use the physical key on it anyway.)


And recently the radio reception is degraded...I'm going to clean the radio/antenna connections and see how it goes.

Pretty sure that I have to replace the IP fairly soon too....I'm not sure if this is a very common issue though.
 

icecap

Veteran Member
Joined
Apr 10, 2007
Location
Chilliwack & Mission BC
TDI
2006.5 Jetta TDI 5Spd Black Anthracite Pkg 1
I had one that I also saw someone on here recently had with their A5. The heater a/c blend air door motor gears stripping out causing a continuous noise coming from under the dash that sounds like one of those electric air compressors you can plug into your cigarette lighter plug to inflate tires. The noise changes when you shift from reverse to foreword and if you use your winshield washers.
 

VLS_GUY

Veteran Member
Joined
Sep 27, 2006
Location
Camarillo, CA
TDI
2002 Bug, Skid Plate, Stage 1 Upsolute
Add another one to the early A4 list:
The antenna corrodes to the point the wire that makes up the screw attached portion of the antenna has no metal in it-just scale. This causes reception problems that produces no fault codes or other obvious symptoms. Just replace the antenna. An easy, cheap fix as long as the threads aren't damaged from corrosion.
 

ChippedNotBroken

Veteran Member
Joined
Dec 29, 2004
Location
Pocono\'s, NYC
TDI
Jetta A4 1999.5 Green
Some of these issues have simple fixes, like the A4 109 relay. Perhaps we should break it down by model year, put in the appropriate forum and include the simple fixes where available.

The early A4 glove boxes all broke, should have been a recall.
 

oilhammer

Certified Volkswagen Nut & Vendor
Joined
Dec 11, 2001
Location
outside St Louis, MO
TDI
There are just too many to list....
The early A4 glove boxes all broke, should have been a recall.
Recalls are for safety related items.... I kinda doubt the glovebox door would fall under that.

"We have found, under certain conditions, the glovebox door may break, and in turn cause the driver to lose control, crash, and possibly die. Please return your car to your nearest authorized Volkswagen dealer for inspection, and if necessary, replacement of your glovebox door." :p

Although, in all honesty, I guess it could injure the passenger in an accident if it was open. And the broken window regulators were taken care of, and that is not really a safety issue either, although technically that was after a lawsuit (same as the sunroof drains).
 

Victor Huge

Veteran Member
Joined
Apr 18, 2009
Location
Alberta
TDI
Mk7 Golf TDI
Should i be snipping the sunroof drain tubes? I have no issues with mine, seems to drain fine, oh man, I just made a rhyme.
 

oilhammer

Certified Volkswagen Nut & Vendor
Joined
Dec 11, 2001
Location
outside St Louis, MO
TDI
There are just too many to list....
Should i be snipping the sunroof drain tubes? I have no issues with mine, seems to drain fine, oh man, I just made a rhyme.
No, you should just be cleaning them like normal at every service as stated in the PM schedule your car came with. If you just keep them clean, there is no problem.

All that "extra" stuff manufacturers place in the PM schedules is there for a reason, not just to take up extra space on a page.
 

Victor Huge

Veteran Member
Joined
Apr 18, 2009
Location
Alberta
TDI
Mk7 Golf TDI
Ahh, I never got a manual with the car... Good thing for this forum!

While you're reading this, can you confirm that a failing DMF creates what feels like gear backlash? I can move my tires back and forth (when the car is in the air) quite a bit in neutral before i can feel it engaging anything. This also manifests as a jerk when letting off the throttle abruptly, although the dog bone isn't that stiff anymore (to be replaced soon!) so it's definitely adding to the situation when driving. Thoughts, good sir?
 

oilhammer

Certified Volkswagen Nut & Vendor
Joined
Dec 11, 2001
Location
outside St Louis, MO
TDI
There are just too many to list....
Sounds to me more like normal gear train play to me, hard to say if it is excessive unless you feel a similar car. The DMF would not cause the issue you are talking about with the wheels in the air.
 

Victor Huge

Veteran Member
Joined
Apr 18, 2009
Location
Alberta
TDI
Mk7 Golf TDI
Ah ok, thanks a lot, I was worried about it but I had none of the other symptoms like rattling or scratching/scraping noises so I figured it was just the transmission. You should have seen the gear oil when I drained it the first time; could have used it as makeup what with all the sparkles in it :(

Oh well, I take care of it now.
 

ChippedNotBroken

Veteran Member
Joined
Dec 29, 2004
Location
Pocono\'s, NYC
TDI
Jetta A4 1999.5 Green
All that "extra" stuff manufacturers place in the PM schedules is there for a reason, not just to take up extra space on a page.
Yea, I was thinking that when I retire I would start following all the maintenance protocols on everything I own. That ought to keep me busy for at least a couple hours every day.
 

FL2AK-tdi

Top Post Dawg
Joined
Apr 19, 2006
Location
Tampa, FL
TDI
'01 Jetta GLS Sedan
I would suggest that brake booster failures are not limited to 2002 MY only, as in the OP. My 2001 pooped a brake booster at about 70k miles.
 
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