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TDI 101 Got a simple/basic TDI question? Are you a newbie (new to the forums). Feel free to post your question here.

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Old June 28th, 2009, 16:36   #1
oilhammer
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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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Last edited by oilhammer; December 21st, 2011 at 14:28.
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Old June 28th, 2009, 16:42   #2
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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)

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Old July 2nd, 2009, 13:53   #3
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Yeah, that is a good idea.
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Old August 26th, 2009, 11:21   #4
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what services should i get done at 155k? keep it smiple. thanks! my new club buddies
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Old August 27th, 2009, 18:31   #5
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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

Last edited by joetdi; August 27th, 2009 at 18:34.
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Old September 5th, 2009, 00:18   #6
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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
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Old September 5th, 2009, 04:36   #7
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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.
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Old September 5th, 2009, 12:12   #8
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Quote:
Originally Posted by oilhammer
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.
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Old March 17th, 2010, 10:08   #9
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oh wow. this is pretty awesome. now I need one for an aaz
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Old March 18th, 2010, 05:48   #10
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A4 early. Broken Glove Box
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Old April 1st, 2010, 11:42   #11
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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. :-)
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Old April 1st, 2010, 11:52   #12
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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.
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Old April 1st, 2010, 11:55   #13
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oh yeah, forgot - heater fan/resistors seem to come up too, in my case heater fan. power steering pump was also replaced.
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Old April 1st, 2010, 15:53   #14
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To the A4 early add Trunk Stuck and crappy radio reception (no am reception)
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Old April 5th, 2010, 10:22   #15
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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.
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