04 pd coolant loss

[PDJetta]

Re: 2004 PD coolant loss

Has any service facility ever had your car out of your presence? This includes vehicle safety inspections at your local gas station. In Virginia we have yearly safety inspections and during my second inspection with my '04, the inspector started to add generic PS fluid without asking me because he noticed it was a little low. I was in the service bay, so I prevented the mishap. I mean it, anything is possible. Even valdalism by someone who dislikes you, or by a service facility hoping you will bring the car back for a repair after a failure.

--Nate

 

[deezelpower]

Re: 2004 PD coolant loss

I'm still waiting for the result from the dealers (yesterday they were so slammed they couldn't even get to my car). I talked with the service advisor and they haven't ever heard of a coolant leak on the TDI's yet, so maybe I'm the guinea pig too

Kinda strange, in that this is the largest dealer in WA and nearly largest seller of TDI's in the US (Chaplins in Bellevue), that they haven't heard of this?? Updates to follow...

 

[deezelpower]

Re: 2004 PD coolant loss

Just got off the phone with Chaplins, they have confirmed it is the EGR cooler, ordering one now. In the meantime I continue to play with the jetta wagon gasser

LOL.

I definitely smell a TSB from this eventually.....

 

[deezelpower]

Re: 2004 PD coolant loss

Just show this to them if they give you any sass --

It got to a point where I was losing a quart every 200 miles, and that's when it finally failed the pressure test.

Also, they replaced my seat heaters and switches, and a plastic part in the rear door lock mechanisms (without my consent), apparently they're having some concerns over that as well. I sneak-peeked at the cost invoice, those EGR coolers go for $460

GET THIS FIXED UNDER WARRANTY!

 

[runonbeer]

Is this cooler the same as teh ALH cooler? I know it is most likely a differnt pn but would it work?

 

[Nutsnbolts]

I know that it IS a different unit- the intakes are totally different between the ALHs and the PDs. I don't know if something could be rigged up...

To those of you who think that you can "block the exhaust pipes and put the coolant lines together": The ALH crowd tried similar measures to eliminate the EGR altogether when the intakes were sooting up. Result? The ECU knows how much of a drop in intake air volume should result from the EGR opening and allowing exhaust gasses into the intake stream, so it would throw a code. Unless the EGR inlet is opened up to another clean air source, you'll have the same issue. Plan accordingly...

-Rich

 

[o2photo]

I just started experiencing coolant loss on my 04 PD. I'm at 62k. I don't know how much yet. It's not leaking externally.

Is the EGR cooler part of the EGR assembly? Is this something I can swap out myself? I have yet to look at everything. I can't find an EGR 'cooler' on any of the online parts sites.

Thanks,

Marc

 

[Long_Range]

The EGR cooler should still be under warranty even at 62K.

Since it's part of the pollution control system. I may be wrong though. Back up in this thread some one stated the price on the cooler.

You don't want to buy one.

 

[runonbeer]

To those of you who think that you can "block the exhaust pipes and put the coolant lines together": The ALH crowd tried similar measures to eliminate the EGR altogether when the intakes were sooting up. Result? The ECU knows how much of a drop in intake air volume should result from the EGR opening and allowing exhaust gasses into the intake stream, so it would throw a code

You could still just eliminate the cooling with out disabling the flow of exhaust. un cooled EGR. NOx would probably go up (although not as much as eliminating the EGR alltogether) but I'll bet intake clogging would be less of an issue. no more coolant going through the cooler -> no more coolant leaking out of the cooler.

Thanks Rich, I haven't had a chance to poke my head behind a PD yet. Timing belt looks like it'll be a snap though.

 

[GolfpdTDI]

Hi guys i've recently had the same coolant loss from my 2001 Golf pd TDI. The car has done 85,000 miles and i now need to keep adding coolant every 200 miles. similar to the other guys on the board, there's a pressure build up in the cooling system which can be heard when the cap is taken off. took it to a mechanic that my dad trusts. He did a pressure check and couldn't find any leaks. I'm no mechanic....but he says its a closed system and so shouldn't be pressurising. He said its probably the head gasket or even the heads. I mentioned the EGR cooler (thanks to you guys here!!!!) and he phoned a friend who works at VW. He also seems to think it was the head gaskets. He said the cooling system shouldn't build the pressure up. is the EGR cooler the same as the EGR vacuum regulator solenoid valve. Has anyone got any more detail about it /pictures so i can take them to the so-called experts. he says if it was his car he'd probably get rid of it but i'm reluctant cos i really enjoy driving it. Need some help guys.

 

[scottmass]

Just started in my 04 golf. Going to call tomorrow. Glad I signed up for this site. Thanks to all, hopefully its covered. I will update. 47000 miles on the car.

 

[whitedog]

For more reading on this important issue, please read these other posts:

Link 1

Link 2

Link 3

 

[Mattie]

My '04 NB started at about 14,000 miles. I called the dealer and told them about it before it went in for the 15000 mile service. No problem they said. A month later I was adding coolant again. It went in for service at 25000 at the end of July and I asked them to check it because I had added twice since the last service. The dealership pressure tested and found nothing. Overfilled the tank and it leaked in my garage after I got it back. Four weeks and I checked the tank and it was below the fill line and the next morning the check light and bell came on and went off after a few miles. I hadn't been to this site for a while and got to reading and sure enough there was the coolant problem. I've called and told them word is out that it is probably the EGR cooler which has been changed by VW on several cars. He did some checking and left a message that the part has been ordered in case it is needed and to bring it in for an appointment. I hate these extra trips. Means my time, fuel, and 250 miles round trip for something that I had in twice already and told them there is a problem. I also have a problem with my windows going back down when they hit the top. They have cleaned and lubed these EVERY time I have had it in and it doesn't help. Irritating.

 

[o2photo]

Anybody have a part number for the EGR cooler? Can't find it anywhere on the net. My coolant consumption seems to be going up. Need to fix it soon.

Thanks!

Marc

 

[PDJetta]

One person here posted a copy of the EGR cooler warranty invoice and the part number was legible. Searching the posts should locate it. The cooler price is about $450 I think.

I mean it, if mine fails outside of warranty, its getting removed, the EGR pipe ports blocked off, and the coolant hoses connected together. Diesels are exempt from emissions testing where I live.

--Nate

 

[o2photo]

Ooops! I see it above. I was looking for EGR cooler, not Gas Cooler. Petrol on the brain...

The bypass plan is looking good to me as well. We are also exempt from emissions.

Thanks,

Marc

 

[tokenhillbilly]

Add one more to the list. '04 Jetta Wagon 34000 miles. Losing about a liter a week, but I drive the heck out of it. Been happening for about a month now.

Is there a dealer in Atlanta that anyone trusts or, at least, will listen to me if I take it too them. Not Gossett in Alpharetta. I had to argue with both the parts and service managers to convince them to sell me 505.01. They said they use 505.00 all the time in diesels and it works just fine.

So far, no dealer has has their hands on it since I have been doing all of the service myself.

 

[whitedog]

Re: 2004 PD coolant loss

Things that go bump on the board

 

[GaGolfSup]

Re: 2004 PD coolant loss

I had mine in over the summer. Same problem EGR cooler. Jim Ellis VW was able to diagnose the problem without any recommendations from me. I haven't been the happiest with them, but for this particular problem they took care of me well. Everything was under warranty. They put me in a rental as they had to wait for parts for four days. Nice Passat, but the 1.8T seemed like a dog compared to my TDI(sorry off subject)

My question is has VW redesigned this part? Or are they simply replacing it with the same part that is going to fail me in another 30,000 miles or so?

 

[Long_Range]

Re: 2004 PD coolant loss

Quote: “Nice Passat, but the 1.8T seemed like a dog compared to my TDI(sorry off subject)”

Oh no that's not off subject. I love to hear real world driving experience. Perhaps the Passat 1.8T had an automatic also? So you never knew what would happen when you pushed the pedal down.

I once had a 1973 Doge high performance car, with automatic, down shifted on me as I was changing lanes on a rain slick road. An OH MY moment later I was traveling backward at 60 mph. Upon returning home I removed the Kick-down rod and tossed it into the scrap bucket. After that if I wanted second gear I pulled the shifter down.

Moral of the story:
Always nice to know what will happen when you input a command into your car. My TDI is very predictable. It just pulls when I push my foot down. Don't have to wait, don't get any surprises. surprises are a very very bad thing for a driver. Especially in bad weather.

Now back to your regularly scheduled programing.

The BEW EGR system will not work in the long term. IMHO
Members have already posted sucseful ways to remove the system. I imagine that will be the long term solution once the cars are off waranty. It's a simpe task and I for one will not spend two weeks pay to purchase an EGR unit every two years. If we start recieving citations in some states for not having an EGR then VW will be at fault and we will see a new and improved unit introduced in a mandatory recall.

Worse things could happen to a car than a little coolant leak.

 

[pruzink]

Sounds like your EGR cooler might have a leak

I have an 04 PD Jetta with 25,000 miles. I have never had to add coolant. Unfortunately, I have seen several posts in here and at Edmunds about EGR cooler failures. If the EGR cooler leaks the coolant is getting pulled in through the engine with your EGR gas and not on the ground. You will also find posts about eliminating the cooler and the EGR valve completely to avoid this problem from happening again.

 

[SUNRG]

i posted the info below to the PD Oil Info & Analyses thread in the Fuels and Lubricants forum:

The UOA below is an example of anitfreeze contaminated oil in a PD that is most likely the result of an EGR cooler leak. The EGR cooler was replaced just after this oil sample was drawn.

The great news is that all other values are excellent, indicating the level of coolant contamination was minimal, but anyone experiencing coolant loss in their PD should bring it in and have the EGR cooler replaced.

FWIW - we did not replace the EGR cooler immediately when coolant loss was first noticed. this PD probably only had 15k on it the first time i added coolant, and oil analyses through 45k showed no antifreeze present. however, sometime after 45k the rate of coolant loss increased significantly and this 50k UOA tested P (positive) for A (antifreeze) presence.

 

[soc993]

My '04 developed the vanishing coolant problem about a month and a half ago at 47,XXX. It is at the dealer now with 49,XXX. Brought it in on Friday, took them a couple hours to track it down to the cooler but sure enough tech showed me the EGR cooler, gunked up with caked on coolant. I am happy they were persistent with tracking down the problem but recommend staying on them to track it down. There were a few times when it seemed like they were ready to call it a day. It helps if you suggest "EGR Cooler". Overall was happy with Hamilton, NJ VW. They got the job done with no hassle.

 

[tca32123]

Add another to the pile

My 04 Jetta started developing a leak back in July. I took it to the dealer in August when I was going on my honeymoon and told them that it was the EGR Cooler. They had the car for a whole week while I was gone and all they did was run a pressure test which came up negative of course.

The leak persisted until finally back on Oct 26th, my CEL finally appeared. I took it back to the dealer, firmly reminded them of what the problem was. They gave me a rental car and sent me on my way. Dealer called later that afternoon and said they diagnosed it as the EGR Cooler and EGR Valve (surprise, eh?). Said the car would be ready in 2 days.

2 days come and go and I show up to get my car back. I'm told at this point the part is on a "red tag" backorder list from the warehouse in Germany. They have no idea when the part will be ready.

This presents a problem as I am out of state at the time fleeing from Hurricane Wilma. I have to go back home in a couple of days and will have to take my rental car (POS Stratus).

Finally get a call on NOV 14th that the car is ready to be picked up. I have to drop everything and drive 650 miles back up to ATL to turn in the rental and pick up my car.

I'm thinking about asking to be reimbursed for the cost difference in having to drive a gasser vs my diesel. I drove the rental about 2K miles while I had it. I figure I spent at least an extra 100 bucks in gas. I haven't done the math yet to get an accurate number, but I know its up there. What are the chances of getting reimbursed?

 

[aozolin]

EGR Cooler Replaced, Jetta traded

First, I want to thank this Forum for informing me of the problem my 2004 Jetta wagon TDI had. This helped when at 49K+ miles, I found my coolant light on and coolant level low. I added a cup of distilled water and drove the Jetta to the dealer to get my 50K service and had them check my coolant system. They found nothing wrong (no leaks) and no explanation for my problem.
Within a week from the 50k service, I was adding a cup of coolant/water each day. I drive typically about 100 miles per day. I returned to the dealer, told them about my EGR cooler research found in your forum and they validated a bad EGR cooler as my problem. They also told me that just the week previous, another EGR cooler was replaced on another Jetta TDI. Funny how this was not discussed on my first visit. I left the car with the dealer for a week since the EGR cooler was backordered. A free loaner was provided.
The EGR cooler was replaced, under warranty even though I brought the car back over 50k (out of warranty for the cooler). My dealer was nice enough to cover warranty since I identified the problem to them at my 50K service, however they didn't replace the EGR Cooler gasket which allowed for an airleak upon applying the accelerator. They ordered the gasket and it arrived four days later, meaning another trip to the dealer.
I never made it back to the dealer, though. The Jetta was traded-in for a new Tacoma. I lost my confidence with the Jetta and VW. There were smaller problems prior to the EGR cooler (rear passenger seat belt, loose front grill insert, involutary opening of the rear window, loose trim piece above the ashtray). To me, the EGR cooler replacement was just a ticking bomb for an unjustified future replacment that I would have to pay for. The VW technician stated that I could prevent the problem from reoccurring by 1) driving the car "harder" to help clean out the EGR valve, and 2) requesting the EGR valve to be cleaned at regular intervals. I shook my head and said no more.
Good luck to you TDI owners, and by wary when your TDI-PD approaches 50K.

 

[TheSpatulaOfLove]

And another happy customer.

45k, and I began to have the EGR problem. I researched here to learn what my symptoms were pointing towards (Thanks TDIClub techies) and marched into two different dealerships in southeast MI. I will protect their identities as I am trying to build a relationship with them for future issues.

I explained what I felt was the problem with the car and asked them specifically to check the EGR Cooler. Both dealerships merely ran pressure tests and stated nothing was wrong. I asked them to explain why I had to add coolant every couple days or every 250 miles. I would get a non-answer. I was drawing painfully close to my 50k mark and getting panicky about this expensive part, so I called in a favor.

I contacted Dwight Harrison VW in GA, where I bought the car. I recently moved to Detroit from Atlanta, and my dealership experiences here in MI make me wish I hadn't.

I called the Service adviser @ DHVW, explained my symptoms to which he interrupted me while I was explaining and said: "Yep, EGR cooler- seen a few of those." I asked him if he could get the part in, was told he would expedite it for me and I drove to Atlanta to have the work done. Pretty sad that I have to trek over 850 miles to get reliable service, huh?

Let me put it this way - the car runs like brand new again. My fuel mileage is back up, my torque is back and I'm not blowing smoke like wildfire.

The tech showed me the EGR cooler and the pipe that connects to it. It was so clogged, we couldn't get a screwdriver in to clean it out. Surprisingly, I didn't throw a CEL until the last 100 miles before getting to the dealer - I only had the coolant light 'b!tching' at me.

Big props to DHVW - If you're in Atlanta, you're lucky. They've taken care of me for 5 years and I will miss visiting them for my monthly oil-changes. I never had to worry that work performed was done incorrectly. I'm tempted to continue to find ways to get to Atlanta to have my service done!

 

[Passatdiesel]

Another EGR cooler, thanks guys !

New member here. Hi all !
I had also problems with coolant loss and hard smoking (Passat TDi PD -02 automatic). Unfortunately when car had first time this coolant loss sign, We think that is head gasket (motor type AJM had lot of these). But quick i noticed that head gasket it's not issue. So i was guite lost, where coolant loss ?

Thanks to this forum I get information about this EGR cooler !
Now coolant lines are connected together, and the EGR pipes plocked off.

Car working very well! No smoking, no coolant loss, no purl sounds inside and more power.

Thanks,

 

[pruzink]

Have seen so many posts on EGR cooler leaks

I have seen so many posts on this website and Edmunds about the EGR coolers on these things starting to leak that I have been keeping a close eye on my coolant level to catch it soon after it starts. I just went over 26,000 miles and I'm just starting to see coolant loss. A lot of the dealers haven't been very good at diagnosing the problem so I will se how mine does. I just followed someone's advice and posted a complaint at "http://www-odi.nhtsa.dot.gov/ivoq/". I feel that this issue is spread wide enough that VW needs to deal with it and come up with an adequate solution. People that are out of warranty are blocking off the EGR connections and connecting the 2 coolant hoses because it is a $900 repair. That is why it is important for everyone to register their complaint if they have this problem so it forces VW to come up with a permanent solution.

 

[spicy_red]

I have seen several posts in here and at Edmunds about EGR cooler failures.

anybody have this Edmunds reference they could share with me?
Thanks!

 

[j_nickels]

Just thought I'd add myself to the list. I have a (recently purchased CPO) '04 GOLF TDI with 30,000 and have taken it in to a dealer 3 times due to coolant loss. 1st time they said air may have been trapped in the system and when it "burped" the coolant level dropped, they replaced coolant (the coolant system passed a pressure test). Maybe a week or two later was back in, this time they said the coolant tank needed a new cap--done. Another week, I'm back in and they say the whole coolant tank and sensor need replacing--ok, got it. Another two weeks and the coolant light is back on. But not after the MIL turned on. My partner took the car in and was eventually told they were going to replace the intake manifold, which has been on order. When I take the car in I'll be sure to mention the EGR cooler. Isn't the EGR part of or connected to the intake manifold? I'm wondering if it'll already be replaced along with the intake manifold. Fortunatley, we haven't had to spend a dime.