2006 Jetta TDI 1.9L BRM Heater Hose Fitting Busting/ Coolant Pouring Out

PoodleBalls

New member
Joined
Aug 6, 2022
Location
San Antonio, TX
TDI
2006.5 VW Jetta TDI 1.9L Automatic
Hi yall!

New member here and first post but I have been reading on here since we bought our car in Feb of this year. This car has been one thing after another since we got it. That being said, the main issue is the one that I’m posting about here. Sorry if this is too long!

Car Details: 2006 VW Jetta TDI 1.9L Automatic- manufactured in 08/2006 so I think that makes it the MK 5.5?

Bought the car in Feb 2022 and it had a coolant leak. We quickly determined that the leak was caused by a major split in the upper heater hose (part number 1K0-122-157-HP) that connects to 1K0-122-291H and that it needed to be replaced. Since our car was manufactured after 07/2006, the actual dual hose set up was a bit pricy so we purchased a gates hose in the correct size for just that side with a 90* bend on one end and hooked it all up.

At the end of April, the leak returned. This time though the coupler (1K0-122-291H) was shattered so we ordered a new one and replaced it. After just 3 days of just moderate driving, the new coupler busted but this time looked melted. We didn’t get an OEM part and just chocked it up to that one being faulty. Once again, after two days of driving this time, it busted again, this time looking more broken than melted and just like the lip of it, rather than at the bend like it busted both previous times.

We’re at a loss. Called our local VW dealer this time to see if they happen to have the coupler and hose in stock so we can go OEM. They didn’t but when I told the parts guy what was up he suggested to test the coolant pressure and said it could have something to do with the radiator or the water pump. We are hoping to be able to do this this weekend and I will post the results here too. We have VCDS and can rent gauges and such if needed. We would love for this car to at least be reliable enough that we can drive it when we need it!

Something else to mention, though I am not sure if it is related or not: the AC in the car also doesn’t work. It blows fine and everything but is not cold despite being charged properly (I think)

Any ideas or suggestions of what could be going on here or what else we need to check or test?

Is it just the fact that we are using aftermarket parts? I would hate to shell out for the OEM parts and it continue happening and ruin those more expensive parts.

What is the normal pressure range for the cooling system? If it is over pressurized, any suggestions for narrowing down the cause of the issue? I have quite a bit of car experience but not so much with this specific issue.

Posting the VCDS Autoscan below. I know it shows more issues than mentioned above but we just haven’t finished recoding it after doing the MFSW retrofit so that should explain some things here. Other things that show malfunction, I have no clue what is causing those yet but they are not the priority at the moment. lol I will put the Advanced Measuring Blocks for the HVAC system in a comment too in case it is related or anyone can give tips on that situation too.

Thank y'all so much for any help/hints/suggestions y'all can provide!
 

PoodleBalls

New member
Joined
Aug 6, 2022
Location
San Antonio, TX
TDI
2006.5 VW Jetta TDI 1.9L Automatic
Sunday,17,July,2022,01:05:07:54947

VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x64

VCDS Version: 22.3.1.4 (x64) HEX-V2 CB: 0.4615.4

Data version: 20220407 DS337.0

www.Ross-Tech.com

VIN: 3VWST71K26M022237 License Plate:

Chassis Type: 1K (1K0)

Scan: 01 02 03 08 09 0F 15 16 17 19 25 42 44 46 52 56 62 65 72 7D

VIN: 3VWST71K26M022237 Mileage: 249490km-155025miles

00-Steering Angle Sensor -- Status: OK 0000

01-Engine -- Status: Malfunction 0010

02-Auto Trans -- Status: OK 0000

03-ABS Brakes -- Status: Malfunction 0010

08-Auto HVAC -- Status: OK 0000

09-Cent. Elect. -- Status: Malfunction 0010

0F-Digital Radio -- Status: Malfunction 0010

15-Airbags -- Status: OK 0000

16-Steering wheel -- Status: Malfunction 0010

17-Instruments -- Status: OK 0000

19-CAN Gateway -- Status: Malfunction 0010

25-Immobilizer -- Status: OK 0000

42-Door Elect, Driver -- Status: OK 0000

44-Steering Assist -- Status: Malfunction 0010

46-Central Conv. -- Status: OK 0000

52-Door Elect, Pass. -- Status: OK 0000

56-Radio -- Status: Cannot be reached 1100

62-Door, Rear Left -- Status: OK 0000

65-Tire Pressure -- Status: Not registered 0011

72-Door, Rear Right -- Status: OK 0000

7D-Aux. Heat -- Status: Malfunction 0010

-------------------------------------------------------------------------------

Address 01: Engine Labels: 038-906-016-BEW.lbl

Part No SW: 03G 906 016 AC HW: 028 101 223 9

Component: R4 1,9L EDC G000DG 7551

Revision: --H02--- Serial number: VWZ7Z0F4156180

Coding: 0050078

Shop #: WSC 00066 000 00000

VCID: 6491A2334256D51B4B7-8030

VINID: 0E69E390705B0867400820831CA6A8B0A3



1 Fault Found:

008581 - Engine Coolant Temp Sensor on Radiator Outlet (G83)

P2185 - 000 - Signal too High

Freeze Frame:

Fault Status: 01100000

Fault Priority: 0

Fault Frequency: 1

Reset counter: 255

Mileage: 249498 km

Time Indication: 0

Date: 2000.00.00

Time: 01:03:07



Freeze Frame:

RPM: 0 /min

Speed: 0.0 km/h

Load: 0.0 %

Voltage: 12.16 V

Bin. Bits: 00101000

Temperature: 87.3°C

Temperature: 73.8°C



Readiness: 0 0 0 0 1



-------------------------------------------------------------------------------

Address 02: Auto Trans Labels: 02E-927-770.clb

Part No SW: 02E 300 043 HW: 02E 927 770 AE

Component: GSG DSG 070 1126

Revision: 04507000 Serial number: 00000606120210

Coding: 0000020

Shop #: WSC 00066 000 00000

VCID: 51FF7BE72DE450B3101-8004



No fault code found.



-------------------------------------------------------------------------------

Address 03: ABS Brakes Labels: 1K0-907-379-MK60-F.lbl

Part No SW: 1K0 907 379 AC HW: 1K0 907 379 AC

Component: ESP FRONT MK60 0101

Revision: 00H11001

Coding: 0021122

Shop #: WSC 00066 000 00000

VCID: 73B3D16FF7B842A3C2D-8026



3 Faults Found:

01435 - Brake Pressure Sensor 1 (G201)

005 - No or Incorrect Basic Setting / Adaptation

01423 - Lateral Acceleration Sensor (G200)

005 - No or Incorrect Basic Setting / Adaptation

00778 - Steering Angle Sensor (G85)

005 - No or Incorrect Basic Setting / Adaptation



-------------------------------------------------------------------------------

Address 08: Auto HVAC Labels: 1K0-820-047.lbl

Part No: 1K0 820 047 FQ

Component: Climatic PQ35 120 0606

Shop #: WSC 00000 000 00000

VCID: 78A9E643EEDE21FBF7F-802C



No fault code found.



-------------------------------------------------------------------------------

Address 09: Cent. Elect. Labels:. 3C0-937-049-23-M.lbl

Part No SW: 3C0 937 049 P HW: 3C0 937 049 P

Component: Bordnetz-SG H46 1501

Revision: 00H46000 Serial number: 00000000412431

Coding: 14018E234004150007140000001400000008730B5C0000

Shop #: WSC 00066 000 00000

VCID: 3635287BA44A178B253-8062



Subsystem 1 - Part No: 1K1 955 119 E Labels: 1KX-955-119.CLB

Component: Wischer 290102 020 0501

Coding: 00038805

Shop #: WSC 00066



1 Fault Found:

00987 - Lamp for Brake Light; Left (M9)

012 - Electrical Fault in Circuit

Freeze Frame:

Fault Status: 01101100

Fault Priority: 1

Fault Frequency: 1

Reset counter: 5

Mileage: 249498 km

Time Indication: 0



Freeze Frame:

ON

Voltage: 12.15 V

ON

ON

OFF

OFF

OFF





-------------------------------------------------------------------------------

Address 0F: Digital Radio Labels: 8E0-035-593-SIR.lbl

Part No SW: 8E0 035 593 D HW: 8E0 035 593 D

Component: SDAR SIRIUS H03 0060

Revision: 00000000 Serial number: AUZ4Z7F6018083

Shop #: WSC 00000 000 00000

VCID: 2A0D0C0B60F2436BB1B-807E



2 Faults Found:

02635 - Tuner Not Enabled/Activated

000 - -

Freeze Frame:

Fault Status: 01100000

Fault Priority: 7

Fault Frequency: 1

Reset counter: 5

Mileage: 249498 km

Time Indication: 0

Date: 2000.00.00

Time: 01:03:09



01304 - Radio

008 - Implausible Signal

Freeze Frame:

Fault Status: 01101000

Fault Priority: 5

Fault Frequency: 1

Reset counter: 5

Mileage: 249498 km

Time Indication: 0

Date: 2000.00.00

Time: 01:03:08





-------------------------------------------------------------------------------

Address 15: Airbags Labels: 1K0-909-605.lbl

Part No SW: 1K0 909 605 Q HW: 1K0 909 605 Q

Component: 6A AIRBAG VW8R 033 7900

Revision: 04033000 Serial number: 0038LD099VBJ

Coding: 0013889

Shop #: WSC 00066 000 00000

VCID: 3A2D3C4B9052F3EBC1B-806E



Subsystem 1 - Part No: 1K0 959 339 F

Component: BF-Gewichtsens. 007 0005



Subsystem 2 - Serial number: 6332MSME11686B1DI



Subsystem 3 - Serial number: 6342MSME0E6D2546M



Subsystem 4 - Serial number: 6351HSME0A0F0D24B



Subsystem 5 - Serial number: 6361HSME096D4E64O



Subsystem 6 - Serial number: 63727SME22080915U



Subsystem 7 - Serial number: 63827SME26752961%



No fault code found.



-------------------------------------------------------------------------------

Address 16: Steering wheel Labels: 1K0-953-549-MY8.lbl

Part No SW: 1K0 953 549 AJ HW: 1K0 953 549 AJ

Component: J0527 034 0070

Coding: 0013021

Shop #: WSC 00066 000 00000

VCID: 7AADFC4BD0D233EB81B-802E



Subsystem 1 - Part No: XXXXXXXXXXX

Component: E0221 007 0050



1 Fault Found:

00888 - Wiper Switch for Intermittent Operation (E22)

014 - Defective



-------------------------------------------------------------------------------

Address 17: Instruments Labels: 1K0-920-xxx-17.lbl

Part No SW: 1K0 920 953 J HW: 1K0 920 953 J

Component: KOMBIINSTRUMENT 3HL 1610

Revision: V0003000 Serial number: VWZ7Z0F4156180

Coding: 0023203

Shop #: WSC 00066 000 00000

VCID: 323D146B48220BAB09B-8066



No fault code found.



-------------------------------------------------------------------------------

Address 19: CAN Gateway Labels:. 1K0-907-530-V2.clb

Part No SW: 1K0 907 530 H HW: 1K0 907 951

Component: J533__Gateway H12 0150

Revision: H12 Serial number: 31001065271442

Coding: 3F3F0B6007001002

Shop #: WSC 00066 123 12345

VCID: 2C010A136A065D5B437-8078



2 Faults Found:

01304 - Radio

004 - No Signal/Communication

Freeze Frame:

Fault Status: 01100100

Fault Priority: 2

Fault Frequency: 1

Reset counter: 5

Mileage: 249498 km

Time Indication: 0

Date: 2000.00.00

Time: 01:03:13



01044 - Control Module Incorrectly Coded

000 - -

Freeze Frame:

Fault Status: 01100000

Fault Priority: 1

Fault Frequency: 1

Reset counter: 5

Mileage: 249498 km

Time Indication: 0

Date: 2000.00.00

Time: 01:03:13





-------------------------------------------------------------------------------

Address 25: Immobilizer Labels: 1K0-920-xxx-25.clb

Part No SW: 1K0 920 953 J HW: 1K0 920 953 J

Component: IMMO 3HL 1610

Revision: V0003000 Serial number: VWZ7Z0F4156180

Shop #: WSC 00000 000 00000

VCID: 323D146B48220BAB09B-8066



No fault code found.



-------------------------------------------------------------------------------

Address 42: Door Elect, Driver Labels:. 1K0-959-701-MAX3.clb

Part No SW: 1K0 959 701 AE HW: 1K0 959 793 P

Component: J386 TUER-SG FT 1519

Revision: 71009005 Serial number: 00000504698316

Coding: 0001205

Shop #: WSC 08220 444 85687

VCID: 71BFDB678DA470B3301-8024



No fault code found.



-------------------------------------------------------------------------------

Address 44: Steering Assist Labels: 1Kx-909-144-G2V3.clb

Part No: 1K1 909 144 L

Component: EPS_ZFLS Kl.070 H07 1806

Shop #: WSC 02069 000 90108

VCID: 34311273B236059B1B7-8060



2 Faults Found:

02546 - Steering Limit Stop

005 - No or Incorrect Basic Setting / Adaptation

Freeze Frame:

Mileage: 249480 km

Temperature: 47.0°C

Voltage: 12.10 V

Voltage: 11.90 V



00778 - Steering Angle Sensor (G85)

005 - No or Incorrect Basic Setting / Adaptation

Freeze Frame:





-------------------------------------------------------------------------------

Address 46: Central Conv. Labels:. 1K0-959-433-MAX.clb

Part No SW: 1K0 959 433 CD HW: 1K0 959 433 CD

Component: KSG PQ35 RDK 051 0215

Revision: 00051000 Serial number: 00000000000000

Coding: 13900F880186281B0904058FB0880F0488DCA0

Shop #: WSC 00066 000 00000

VCID: 74B1D273F2B6459BDB7-8020



Subsystem 1 - Component: Sounder n.mounted



Subsystem 2 - Component: NGS n.mounted



Subsystem 3 - Component: IRUE n.mounted



No fault code found.



-------------------------------------------------------------------------------

Address 52: Door Elect, Pass. Labels:. 1K0-959-702-MIN3.clb

Part No SW: 1K0 959 702 P HW: 1K0 959 792 L

Component: J387 TUER-SG BT 1125

Revision: 12006001 Serial number: 00000063468722

Coding: 0001204

Shop #: WSC 00066 000 00000

VCID: 3C213A539A66CDDBD37-8068



No fault code found.



-------------------------------------------------------------------------------

Address 56: Radio

Cannot be reached



-------------------------------------------------------------------------------

Address 62: Door, Rear Left Labels:. 1K0-959-703-GEN3.clb

Part No SW: 1K0 959 703 Q HW: 1K0 959 795 J

Component: J388 TUER-SG HL 1115

Revision: 12004001 Serial number: 00000000214439

Coding: 0001168

Shop #: WSC 00066 000 00000

VCID: 3E25305B8C7ADFCBFD3-806A



No fault code found.



-------------------------------------------------------------------------------

Address 65: Tire Pressure Labels: 3C0-959-433-65.lbl

Part No SW: 1K0 959 433 CD HW: 1K0 959 433 CD

Component: RDK 0420

Revision: 00051000 Serial number: 00000000000000

Coding: 0100101

Shop #: WSC 00066 000 00000

VCID: 74B1D273F2B6459BDB7-8020



1 Fault Found:

01521 - Sensor for Tire Pressure

004 - No Signal/Communication

Freeze Frame:

Fault Status: 01100100

Fault Priority: 4

Fault Frequency: 1

Reset counter: 255

Mileage: 249498 km

Time Indication: 0

Date: 2000.00.00

Time: 01:03:08





-------------------------------------------------------------------------------

Address 72: Door, Rear Right Labels:. 1K0-959-704-GEN3.clb

Part No SW: 1K0 959 704 Q HW: 1K0 959 794 J

Component: J389 TUER-SG HR 1115

Revision: 12004001 Serial number: 00000000219510

Coding: 0001168

Shop #: WSC 00066 000 00000

VCID: 3FDB4D5F8B70D6C3F65-806A



No fault code found.



-------------------------------------------------------------------------------

Address 7D: Aux. Heat Labels: 1K0-963-235.lbl

Part No SW: 1K0 963 235 E HW: 1K0 963 235 E

Component: PTC-Element 0404

Revision: 00800000 Serial number:

Shop #: WSC 00000 000 00000

VCID: 2D070717511C5453549-8078



1 Fault Found:

00361 - Heater Element for Auxiliary Heater (Z35)

014 - Defective



End----------(Elapsed Time: 01:31, VBatt start/end: 12.2V/12.2V)-----------
 

PoodleBalls

New member
Joined
Aug 6, 2022
Location
San Antonio, TX
TDI
2006.5 VW Jetta TDI 1.9L Automatic
Group 1:
Compressor Shut-Off Code: 0.0
Engine Speed: 800/min
Vehicle Speed: 0.0km/h
Standing Time: 03:06
Group 2:
Compressor Current (actual): *This field is blank*
Compressor Current (specified): 0.820 A
Compressor Speed: 1000/min
Compressor Load: 4.8 Nm
Group 3:
Refrigerant Pressure: 10 bar
Radiator Fan Activation (actual): 38.8%
Radiator Fan Activation (spec.): 39.2%
Engine Speed Increase: ON
Group 4:
Outside Temp (unfiltered): 32.0*C
Outside Temp (filtered): 32.0*C
*Blank Box*
Coolant Temperature: 42.0*C
Group 5: Outlet/Footwell Blower Temperature
Outlet Blower Temperature: 35.0*C
*Blank Box*
Footwell Blower Temperature: 37.0*C
NA
Group 6:
Evaporator Temperature: 33.0*C
Interior Temperature: 37.0*C
NA
NA
Group 7:
Fan/Blower Status: ON
(no units): 3.0
(no units): 1.0
System Voltage (Terminal 30): 14.00V
Group 8:
Status Terminal 15: ON
*blank box*
Signal Damping: 0.0%
(no units): 2.0
Group 9: Electrical Heaters
Rear Window Heater (actual): Off
Rear Window Heater (specified): Off
PTC Heater (actual): Off
PTC Heater (specified): 0.0
Group 10:
PTC Heater Driver Intention: Off
Heater Off: Off
Parking Heater Condition: Not Installed
(no units): 0.0
Group 11: Fresh Air Recirculating Air Flap
*blank box*
Specified Value: 100.0
N/A
N/A
Group 12: Left Temperature Flap
Current Value: 29.0
Specified Value: 32.0
Cold Stop: 32.0
Warm Stop: 221.0
Group 13+:
Error Not Available
 

turbodieseldyke

Veteran Member
Joined
Jun 6, 2010
Location
Free Mustache Rides
TDI
98 jetta
Pressure should be around 15psi, iirc. Sounds to me like your parts are crap, made of crap material. If you had a high pressure problem, it would blow out your hoses and heater core, or out the reservoir cap, long before it broke a plastic coupler -- which is reinforced on the outside with rubber hoses and clamps.

You didn't happen to buy your parts from a guy called "Hans" or "Prothe", i hope.
 
Last edited:

Rx7145

Veteran Member
Joined
May 21, 2017
Location
Ohio
TDI
2006 Jetta BRM
Do you mind posting a picture of the part that keeps melting or breaking I can’t picture it but it does sound like bad parts.
As far as the air-conditioning not working sounds like classic refrigerant control valve symptoms.
 

sptsailing

Veteran Member
Joined
Jul 9, 2010
Location
Safety Harbor, FL
TDI
2006 Jetta Manual, stock with Panzer Plate & Franko6 modified EGR cooler & CAM
Hi yall!

New member here and first post but I have been reading on here since we bought our car in Feb of this year. This car has been one thing after another since we got it. That being said, the main issue is the one that I’m posting about here. Sorry if this is too long!
<Snip>
<end snip>

Thank y'all so much for any help/hints/suggestions y'all can provide!
The heater hoses are position seemingly strategically under where engine oil drips will routinely fall on them. Since they are not designed to withstand oil, they will fail after this occurs. I made an aluminum shield to protect my replacement hoses when I found this out, which even with new gaskets and seals still manages to get oil on it, but my hoses no longer do.
 
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