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VW MKV-A5 Golf/Jettas Discussions area for A5/MkV Jetta/Golf (2005/2006 PD and 2009 CR).

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Old August 13th, 2019, 18:59   #1
Veteran Member
Join Date: May 2007
Location: Rosharon, Tx
Fuel Economy: jetta 40-50
Default MkV BRM TDI Jetta Starting Problem

I've got a MkV BRM Jetta that's developed this weird starting problem after a DMF replacement. So for a while it was making this god awful rattle that I (with the help of tdiclub, r/tdi, etc.) determined was the dual mass flywheel going out, I started taking everything apart to complete the job, and after an absolute *nightmare* of getting parts and having to send them back (and waiting on the right ones), bad weather, very little time to devote to the project, and constantly running into problems that required specific tools, etc, the car ended up sitting completely apart in the elements for about two months. I took every precaution to plug up exposed internals, putting a tarp around the tranny/engine, etc, but I can't shake the feeling that this has something to do with all this because the problem didn't start until everything was put back together.

That being said... Aside from the disgusting amount of time it took to complete, the job went smoothly, everything went where it should've and the way it should've. Fast forward to april when everything got put back together and the problem starts: From turning the key it takes anywhere from 8 seconds to 40 seconds for the engine to start. It hasn't *failed* to start just yet, it just takes forever to. There is also a significant loss of power, 0-60 in 3-4 minutes. Since april I have replaced the throttle body, MAP sensor, MAF sensor, N75 valve, fuel filter, lift pump, fuel lines, fuel line clamps, fuel filter housing bolts, glow plugs, and air filter to try and address this problem but so far no success. The lift pump is pressuring up almost instantly, so fuel is not leaking back to the tank. Can blow compressed air in the lines back towards the engine, seems to maintain pressure. Hence don"t think it is bleeding off in the injectors.Is it possible that the cam or crank shaft positioning sensors are bad??? Any advice would be helpful, I threw up my hands and bought a 2015 Gulf Wagon last month to replace it but now I'd like to sell the car to help pay for the new one.


Video of the problem in action:


Last edited by p930man; August 16th, 2019 at 16:11. Reason: more information
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Old August 17th, 2019, 15:19   #2
Join Date: Sep 2005
Location: Spicewood, Tx.
Fuel Economy: 49.3, 48, 21.2,19.99

These jobs and further more the diagnoses are testing. since I am not there, can we assume all the connectors are pulled in properly and VCDS has been run to detect any minor problems?

If the job was done correctly, everything has been plugged in and VCDS doesn't show any faults...and the car started fine and ran good except for a little noise before, then I would stop throwing parts at it and start doing some diagnosics.

Was any other work performed at the time?..i.e. timing belt etc.
2018 F150 3.5 ECO 3.55 10spd 20s 2tone 26mpg 2turb
2006.5 DE DSG, RC2, Sunroof, 200K miles, 61MPG best
2005.5 Jetta-5 SP LSD Spec S2 130K ELF506 10-30W OCI=20k ORIGINAL CAM RSB Diesel custom 2.5DP/3" SS Pkg 1 Auto-dim mirror auto-WW auto-climate 248tq=150HP RC2 lowered 312 brakes
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Old August 28th, 2019, 09:45   #3
Veteran Member
Join Date: May 2007
Location: Rosharon, Tx
Fuel Economy: jetta 40-50

Thanks Mach1, We bit the bullet and bought the VCDS, CODES ALL OVER THE PLACE. The major code we see is implausible signal coming from cam shaft position sensor. So we were in the process of replacing the sensor, my stepson just out of the Army was giving me the assist, actually this is his car. We got assess to the 10mm bolt below the cam shaft pulley that holds the sensor in place. Don't know how but he sheared the bolt off in the block, new curse words were created over that disaster. He swears he was just loosing the bolt. I guess I will need to take the right motor mount loose and raise the engine to get assess to the sheared bolt and drill and tap, Has anyone sheared this bolt before? We removed the valve cover and inspected the cam, the cam appears to still have the good shinny harden outer surface and the lobs show no signs of abnormal ware
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