Hard Start / No Start - Is your intercooler frozen? Check Here!

[stickboy]

I puchased a 2010 JSW about 2 years ago, insisted they install the TSB at that time if they wanted my $ and they did without hesitation. I thought I was in the clear, I've been a TDI driver since the beginning and before with an 92 ecodiesel.
Well, this winter 3 instances of icing, managed to fix the first 2 myself. Pulled a quart of ice and 3 cups of water out of the lower hose. Called VWoa, horrible service, had it towed to verify water and alas none AND they stated there is no updated TSB and that my 2011 TSB was the same then as it is now. Now it's froze up again and I'm having it towed to the dealer 100 miles away.
Does anyone have info from VW showing the switch to the 10c valve. I assume I have the 0c valve since the TSB was performed in 2011.
It's hard to not start looking elsewhere, I bought this car to be reliable and like others I have this little gut feeling every time I turn the key that it won't start.

 

[SundanceGS]

I puchased a 2010 JSW about 2 years ago, insisted they install the TSB at that time if they wanted my $ and they did without hesitation. I thought I was in the clear, I've been a TDI driver since the beginning and before with an 92 ecodiesel.
Well, this winter 3 instances of icing, managed to fix the first 2 myself. Pulled a quart of ice and 3 cups of water out of the lower hose. Called VWoa, horrible service, had it towed to verify water and alas none AND they stated there is no updated TSB and that my 2011 TSB was the same then as it is now. Now it's froze up again and I'm having it towed to the dealer 100 miles away.
Does anyone have info from VW showing the switch to the 10c valve. I assume I have the 0c valve since the TSB was performed in 2011.
It's hard to not start looking elsewhere, I bought this car to be reliable and like others I have this little gut feeling every time I turn the key that it won't start.

Stickboy, I don't know how to determine which version of the cold weather kit we have gotten (whether the internal flap actuates at 0 degree F or 10 degree F). I had mine installed in February of 2013 and have no idea which I received.

I second the motion of being very interested in how to find out. Can anyone advise?

 

[Jayg]

I just got an email back from the service department where my car has been for weeks. It hasn't run right after the IC kit was installed. (Check engine lights, hiccups) The codes are 20D8 exhaust after treatment fuel supply performance and 2413 egr system performance mechanical malfunction. Almost 40 days in the shop in the last year. 21k miles.

Sorry to clutter this thread but it is relevant. I had my own thread but it was consolidated to this one. Just posting in case others have issuues AFTER the IC kit goes on.

 

[wrpercival]

Given all of the recent discussion about intercooler icing, I decided to use foam pipe insulation to block the lower grill area of my wagon. I'd guess it has cut the time for the engine to warm up in half.
This morning during my commute from the Maryland suburbs I transitioned from rain to snow - 38 degrees to 32 degrees - the kind of conditions often described as causing condensation in the intercooler.
Thought the group might be interested in the following photo showing the snow accumulation on the grill. I'm assuming this would have otherwise passed through to the intercooler.
I have not experienced any of the symptoms of icing, nor have I pulled the hoses yet to check on water accumulation, but I plan to soon. So I am not suggesting this is a solution. But based on the snow build-up on the grill, I'm hoping this might help reduce the potential for condensation forming.

https://www.evernote.com/shard/s21/...90be101e3b1e/5dfa2ee22d3075bbedea2a482977cee1

 

[tylerlaw]

I have a 2012 Golf Wagon, purchased 2 years ago. This is the first winter I've had problems with it. Early in the season (before it was even really cold), I had a hard start, stumbling etc. All signs of water, I now know. It went to the dealer (a week later since they couldn't get me in). The cold weather intercooler went on and away I go.

Last week, a few months after the IC change, I get a block from my house and my glow plug light starts flashing. The car feels like it has no power. I pull over, turn the car off, restart it and it seems fine. Back to the dealer that morning and they find a chunk of ice.

They had to order a valve which they explained closes the intercooler flap at a different temperature.

Has anyone else have experience with this? They said they've installed one other one and haven't had any complaints again from that owner.

Also of interest, I open my trunk when I get home and there's a piece of hard piping, U shaped, in there. I called the dealer and they forgot to tell me that it's a part they removed, and to hold onto it incase there are problems with the valve come summer. That doesn't give me a lot of confidence in what they've done to the car. The removed part is 3C0 129 618 D, air intake hose pipe.

I'm to the point that I'm considering putting it up for sale and moving on. I really don't want to take the hit on selling a 2 year old car though.

 

[msantram]

I went into my dealer this am to get preventative checkup after experiencing slight jerking and hiccups. After opening up the pipes, they did not find "water", but listed cause as "moisture buildup in intercooler piping". the tech noted the correction as "inspect intercooler and piping, observe excessive moisture and BLOWBY mixture. install cold weather intercooler kit, recheck ok."

I'm a bit concerned about the Blowby mixture comment. Any thoughts or recommendations?

 

[RES]

It got warmer outside so I removed the pipe insulation and re-installed the snorkel and the intake air box. I noticed that the rear wall of the plastic air box is missing. Just as though most of the air goes straight through the box (open in the back), and only small part of it gets sucked up into the snorkel. This is the box located right under the hood, behind the upper grille, driver's side. Maybe it was like this when I removed it but I didn't notice. Could anybody please confirm if this set up is normal or I am missing a rear panel/plate on the box? Thank you in advance.

I assume you are referring to the box which has a slotted grill for air to flow in just above the grill. When you remove the top cover you can see that the back face is open to allow air to enter from the engine compartment.

 

[Samcar222]

I went into my dealer this am to get preventative checkup after experiencing slight jerking and hiccups. After opening up the pipes, they did not find "water", but listed cause as "moisture buildup in intercooler piping". the tech noted the correction as "inspect intercooler and piping, observe excessive moisture and BLOWBY mixture. install cold weather intercooler kit, recheck ok."

I'm a bit concerned about the Blowby mixture comment. Any thoughts or recommendations?

Sounds like you need to drive the car harder to 'blow out the cobwebs', so to speak. One full throttle run a day once warmed up works nicely (IMO). Some will tell you driving style has nothing to do with it, but these motors like to be worked, not lug around at 1200 rpm all day. Just my thought.

 

[VeeDubTDI]

The blowby from the crankcase vent is what turns the moisture into the green snot that everyone has been posting pictures of. It's a normal component of the charge air (because that's where the CCV vents) but when combined with the excessive moisture turns into a frothy green sludge.

 

[msantram]

Thx Sam, appreciate the note. I've been spending too much time working in front of my computer and not enough time on the road. I have been taking it easy on the car the last month driving slower (e.g 55 mph) and hypermiling whenever possible.

I'll put the engine to work for sure. thx!

 

[msantram]

The blowby from the crankcase vent is what turns the moisture into the green snot that everyone has been posting pictures of. It's a normal component of the charge air (because that's where the CCV vents) but when combined with the excessive moisture turns into a frothy green sludge.

ah righ, thx VeeDub. i'm re-reading the thread from start to finish now.

 

[VeeDubTDI]

ah righ, thx VeeDub. i'm re-reading the thread from start to finish now.

Bravo for that! It's pretty all over the place, but it's a great read.

 

[msantram]

Bravo for that! It's pretty all over the place, but it's a great read.

Indeed! So much to learn. Read more, post less

 

[ticketed2much]

I have a 2012 Golf Wagon, purchased 2 years ago. This is the first winter I've had problems with it. Early in the season (before it was even really cold), I had a hard start, stumbling etc. All signs of water, I now know. It went to the dealer (a week later since they couldn't get me in). The cold weather intercooler went on and away I go.

Last week, a few months after the IC change, I get a block from my house and my glow plug light starts flashing. The car feels like it has no power. I pull over, turn the car off, restart it and it seems fine. Back to the dealer that morning and they find a chunk of ice.

They had to order a valve which they explained closes the intercooler flap at a different temperature.

Has anyone else have experience with this? They said they've installed one other one and haven't had any complaints again from that owner.

Also of interest, I open my trunk when I get home and there's a piece of hard piping, U shaped, in there. I called the dealer and they forgot to tell me that it's a part they removed, and to hold onto it incase there are problems with the valve come summer. That doesn't give me a lot of confidence in what they've done to the car. The removed part is 3C0 129 618 D, air intake hose pipe.

I'm to the point that I'm considering putting it up for sale and moving on. I really don't want to take the hit on selling a 2 year old car though.

The part is your intake "snorkel", I would put it back on in spring. Try covering your grill with either a ID parts cover or the pipe foam. It will keep the water in your IC from freezing.

 

[Samcar222]

The part is your intake "snorkel", I would put it back on in spring. Try covering your grill with either a ID parts cover or the pipe foam. It will keep the water in your IC from freezing.

+1, pipe insulation can be used to block the lower grill very well. In 'extreme' cold (below 25*f or so), you can also block the top grille with the IDparts.com sportwagen winter front. Kit includes blocks for the top and bottom openings , very nicely made at $100.

 

[msantram]

weird, my dealer didn't put my intake pipe in my trunk. i'll call them and ask for it, but i'm sure it's too late.

 

[Loafing]

I just got an email back from the service department where my car has been for weeks. It hasn't run right after the IC kit was installed. (Check engine lights, hiccups) The codes are 20D8 exhaust after treatment fuel supply performance and 2413 egr system performance mechanical malfunction. Almost 40 days in the shop in the last year. 21k miles.

Sorry to clutter this thread but it is relevant. I had my own thread but it was consolidated to this one. Just posting in case others have issuues AFTER the IC kit goes on.

I had a litany of mils after my IC job & they finally found vacuum hoses reversed. All was quiet after that. I did not have any negative engine running symptoms while that was going on.

 

[BluGraphTDI]

My father and I both had our 2012 Golf TDIs updated with the intercooler kit in mid January. Simple call to VWOA to report the issues (which were exactly as the TSB described), then coordinated with the service department at our local dealership and within a couple days had the update installed on both vehicles.

It was very painless (surprisingly) and I am very impressed by VW for taking care of it without hassle.

 

[Matt927]

My father and I both had our 2012 Golf TDIs updated with the intercooler kit in mid January. Simple call to VWOA to report the issues (which were exactly as the TSB described), then coordinated with the service department at our local dealership and within a couple days had the update installed on both vehicles.

It was very painless (surprisingly) and I am very impressed by VW for taking care of it without hassle.

Same here. Mentioned the symptoms at the 10,000 mile oil change, dealer left a message on my phone and said they changed "a part" and wanted to keep the car overnight. Picked it up the next day and the kit was installed.

 

[Mfisher]

My father and I both had our 2012 Golf TDIs updated with the intercooler kit in mid January. Simple call to VWOA to report the issues (which were exactly as the TSB described), then coordinated with the service department at our local dealership and within a couple days had the update installed on both vehicles.

It was very painless (surprisingly) and I am very impressed by VW for taking care of it without hassle.

Thats because you are in warranty lol. After that, You are dead to VWoA... I dont expect them to address most issues after warranty, but this is a big one that every car had from the factory. The "wait till the customer has issues vs. a recall" approach is the epitome of horrible customer service.

 

[Loafing]

Thats because you are in warranty lol. After that, You are dead to VWoA... I dont expect them to address most issues after warranty, but this is a big one that every car had from the factory. The "wait till the customer has issues vs. a recall" approach is the epitome of horrible customer service.

I was out of warranty & they covered it no problem.....

 

[path23dv]

I was out of warranty and VW would only pay for parts, not labor. Local dealer quoted +$800 for labor. I did not have the kit installed.

 

[BluGraphTDI]

I was out of warranty and VW would only pay for parts, not labor. Local dealer quoted +$800 for labor. I did not have the kit installed.

Yikes!

The total install took about 3 hours, those must be some well paid technicians....

 

[stickboy]

Update to post 4291.
Had the car towed to the dealer. Surprise surprise they found the lower hose frozen solid. The dealer now believes me that this is a real issue. They called VWoA and mentioned the 0C to 10C change in the valve actuating temperature. When I mentioned this earlier to the dealer they said that my 2011 kit was current and no change had been made. VWoA now was acknowledging this change however there is no documentation evidently. The dealer felt that VWoA was trying to keep this on the DL and fix things as they appeared. The new part will be here tomorrow and installed at no charge to me even though I am at 67k and well out of warranty.

 

[roostre]

..... They called VWoA and mentioned the 0C to 10C change in the valve actuating temperature. When I mentioned this earlier to the dealer they said that my 2011 kit was current and no change had been made. VWoA now was acknowledging this change however there is no documentation evidently .....

If you are able to, please find out if there is a way for the rest of us to determine if our TSB intercooler valves operate at 0 or 10 degrees centigrade.

If there is an identification label somewhere on the part that would be the best, but I can't easily see anything on mine now that it is installed.

Thanks

 

[stickboy]

will do when i pick it up.
dl = down low.

 

[MAXecutive]

I wish I could add input since I had the kit installed recently. I've been driving other vehicles with the recent snow storms in NYC.
I means also out off warranty and VWoA installed the kit with no debate.

 

[HNKS]

+1, pipe insulation can be used to block the lower grill very well. In 'extreme' cold (below 25*f or so), you can also block the top grille with the IDparts.com sportwagen winter front. Kit includes blocks for the top and bottom openings , very nicely made at $100.

This item is out of stock right now. Site indicates that it will take at least two weeks before shipping.

 

[Hyates]

Me too...

Hi Folks. Well, add me to the list! 2012 Golf w/ DSG. 43000 Km (~27000 miles).

Been freezing and dry the past week, and I've had problems with starting and driving all week. Car is garaged at home, but outside during my work day. Temperatures been between 0C and -9C plus windchill to -17C some days. I've had the stumbles, slow cranking, surging, NO cranking symptoms as described on this thread when I leave for home in the afternoon all week, and I'm not too happy about this.

I have an appointment for service in a few days where it will get addressed. I did file a Defect Complaint Form with Transport Canada today as well. I'm in Canada. We have to deal with winter, and the car MUST work in our climate. Glad there's a kit available to hopefully fix the problem.

I've owned 5 turbo-diesel vehicles over the years, all with intercoolers, and none of them has had an issue until this one. This car has been flawless until now.

Thanks for the detailed posts on this matter.

H.

 

[fdizz]

Happened to me for the second time last night. Luckily my Golf was already sitting in the garage. Ripped the hose apart and found A LOT of water. This is unacceptable for a 4 year old car. I will be calling vwoa Monday even though I am way out of warranty at 116k.