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

[GraniteRooster]

Very nice work UberVW - thanks for posting pictures of your new kit and thanks for your persistence. I for one will be contacting VW to ask them what they have to offer. It would seem they've been doing some significant work to put that kit together and I would like to know what it is supposed to do. I haven't talked with my friendly VW rep in a few months - seems like a good time to ask some questions

 

[kenford]

Spoke to my dealer in Winnipeg today and they confirmed that they had received a TSB referring to the same part number as listed earlier.
Will not be a recall but rather a fix on a per case basis. They have ordered the parts to fix my 2010 as it was towed to the shop four times over the winter.

 

[TDiSkater]

Spoke to my dealer in Winnipeg today and they confirmed that they had received a TSB referring to the same part number as listed earlier.
Will not be a recall but rather a fix on a per case basis. They have ordered the parts to fix my 2010 as it was towed to the shop four times over the winter.

Might be nice to get that service bulletin number when you have the work done. It will make the conversation easier as winter approaches. I never like to leave it up to them to find it. I had a couple of weird starts last winter and they totally dismissed me when I asked about intercooler problems.

 

[VolksDudeTDI]

Here's a post from Uwe@RossTech on MyTurboDiesel.
http://www.myturbodiesel.com/forum/33992-post23.html

The TSB Number is in the post

There's now a TSB with a fix for this. It's number 21 11 01 / 2025464 dated May 24, 2011, titled "Frozen Charge Air Cooler – Engine Will Not Start". It calls for installing a 1K0-198-803-B Cold Weather Intercooler Kit.

 

[740GLE]

nice all the ammo we need to make VW step up.

Should this be a sticky with the first post modified and TSB in bold?

 

[GraniteRooster]

nice all the ammo we need to make VW step up.

Should this be a sticky with the first post modified and TSB in bold?

Modified Text of first post to include TSB.

 

[El Dobro]

I wonder if this is a patch and not a cure.

 

[MayorDJQ]

I wonder if this is a patch and not a cure.

Short of eliminating the LP-EGR system--or LP-EGR duty cycle, how else would they cure it w/o affecting emissions?

 

[oxford_guy]

It looks like the repair kit includes a new intercooler, a sensor, and what looks like a valve to let water out.

Thumbs up for that.

 

[El Dobro]

Short of eliminating the LP-EGR system--or LP-EGR duty cycle, how else would they cure it w/o affecting emissions?

Has it been proven that's where the problem comes from?

 

[MayorDJQ]

Has it been proven that's where the problem comes from?

Proven? No. The main source of the problem? Quite likely.

Driving style doesn't seem to matter much, as people who drive spiritedly have had the problem as well as pussyfooters. Region of the country doesn't seem to matter much, as it's happened to people from New England to Texas.

The AHU, ALH, BEW, BRM, and their European counterparts have not experienced the sludging/icing problem. The CR engines have the LP-EGR system, which is introduing moisture to the intercooler. If it were a matter of driving in damp or wet weather, then the earlier generation TDIs should experience the problem. But I never had that problem in 150k and 8 New England winters in my ALHs. 9,900 miles and a few months of winter was enough to produce a TBSP of water & line the hose with green sludge in my '10.

 

[740GLE]

proven only in the sense it's the only thing different/new compared to all other TDIs.

 

[El Dobro]

The CCV system is also new.

 

[MayorDJQ]

The CCV system is also new.

It may be a new design, but a CCV is not new to the TDI engine. It's also not dumping water into the intake system.

 

[quadrun1]

Exciting that there's a "fix", but VW might be correct in making people wait before having this installed.

I drove a SAAB 9-5 in the past and the EGR was problematic, so much so that I think there were 5+ revisions/patches to the system!

My gut tells me that this kit is not the "final answer".

Jason

 

[MayorDJQ]

My gut tells me that this kit is not the "final answer".

It's addressing the symptom, not the cause.

 

[tcp_ip_dude]

Has it been proven that's where the problem comes from?

Probably not to your satisfaction..

 

[bhtooefr]

Proving it once and for all, and posting the proof on TDIClub, would be deleted or locked by a couple of the moderators, as it involves an EGR delete.

 

[El Dobro]

In the CCV hose that goes from the valve cover to the turbo inlet there's something that has wires going to it. Does anyone know what it is? I haven't found it in the CR self-study yet.

 

[MayorDJQ]

In the CCV hose that goes from the valve cover to the turbo inlet there's something that has wires going to it. Does anyone know what it is? I haven't found it in the CR self-study yet.

EWD #127/8 in Bentley mentions a heated CCV N79. That would be my guess.

 

[El Dobro]

There's 5 pages on the new CCV system yet it's not listed. A CCV heater, interesting.

 

[nicklockard]

Tdi's have always had a CCV heater.

 

[Fixmy59bug]

Not just TDI's, but a lot of vw's. My 2000 Jetta 2.0 had a heated ccv valve built into the intake boot which was fed crankcase fumes from the valve cover.

 

[El Dobro]

Interesting, and exactely what purpose does it serve?

 

[nicklockard]

It prevents the CCV from becoming plugged by frozen condensate. The condensate is pulled into the intake air by Bernoulli principle, which cools it off.

 

[MonsterTDI09]

I wonderer why they took this root for the fix? In stead blocking off the I/C in some fashion?I my guess my quot is the answer

 

[bhtooefr]

I go for a quote I stumbled upon on when reading a thread on another forum...

http://zombiehunters.org/forum/viewtopic.php?p=1601928&sid=856033f7c6c09cb691f8edea2096770b#p1601928

But yeah, the Germans are like the Gnomes from D&D. They try a bunch of crazy ****, find something that works, then make it more complicated.

 

[GraniteRooster]

I go for a quote I stumbled upon on when reading a thread on another forum...

http://zombiehunters.org/forum/viewtopic.php?p=1601928&sid=856033f7c6c09cb691f8edea2096770b#p1601928

Kinda looks like they took IFRCFI's valve ideas from page 3 and "germanized" them

 

[IFRCFI]

Kinda looks like they took IFRCFI's valve ideas from page 3 and "germanized" them

I believe, at the time, I was openly laughed at for suggesting a drain valve...

 

[cleaver]

Were we laughing at you or with you...(actually, I was just lurking...)