Jetta TDI died while driving. Requesting guidance

[beowulf_lives]

Hi all,

The motor on my 06 Jetta TDI quit today while driving. I would like some guidance on how to troubleshoot.
My father was driving it and I came over and we rolled it into a parking lot and left it. He said it just died. It's been very hot here.

I was hoping once the motor cooled down it would start. We came back 4 hours later and the motor will turn over but I'm not hearing the fuel pump prime. As you can tell I have VAGCOM but I'm not that familiar with it and only took a full reading, no sensor checks yet.

In reading other posts they mention if the J17 fuel pump relay has failed there should be a code. There isn't one. However last year when my crank sensor was going out it also didn't throw any codes either. That relay is probably original.

The crank sensor was replaced 12 months ago as was the fuel pump (OEM). I do all my own work. I also fixed the cut wiring on the MAF sensor and (poorly) spliced in a new glow plug harness. Fuel filter has been replaced every 5k - 10k miles. I think it was last done maybe 3 or 4 months ago. Vehicle averages a consistent 39 - 41 mpg. It's due to have the timing belt replaced, which would be a good time to replace the cam sensor that's listed below. The camshaft is worn and I can hear a bit of a subsonic WOOF from the exhaust. I believe the EGR and MAF codes are related based on other forum posts. My assumption is these aren't the source of the no start problems, I'm just including them for thoroughness.

The vehicle will be towed back to my home tomorrow and I'll take a closer look.

Monday,25,August,2025,21:18:23:50136
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x64
VCDS Version: 25.3.1.2 (x64)  HEX-V2 CB: 0.4671.5
Data version: 20250604 DS365.0
www.Ross-Tech.com


VIN: 3VWST81K86M724309   License Plate:
Mileage: 483750km-300588mi   Repair Order:



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


Chassis Type: 1K (1K0)
Scan: 01 02 03 08 09 0F 15 16 17 19 25 42 44 46 52 56 62 72 7D

VIN: 3VWST81K86M724309   Mileage: 483750km-300588miles

00-Steering Angle Sensor -- Status: OK 0000
01-Engine -- Status: Malfunction 0010
02-Auto Trans -- Status: OK 0000
03-ABS Brakes -- Status: OK 0000
08-Auto HVAC -- Status: Malfunction 0010
09-Cent. Elect. -- Status: Malfunction 0010
0F-Digital Radio -- Status: Malfunction 0010
15-Airbags -- Status: Malfunction 0010
16-Steering wheel -- Status: OK 0000
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: OK 0000
46-Central Conv. -- Status: Malfunction 0010
52-Door Elect, Pass. -- Status: Malfunction 0010
56-Radio -- Status: Cannot be reached 1100
62-Door, Rear Left -- Status: OK 0000
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: --H01---    Serial number: VWZ7Z0E2989693
   Coding: 0050078
   Shop #: WSC 00066 000 00000
   VCID: 649673AA225782AA0B1-8030
   VINID: 0E69E390805B2067470840C02414C6B012

6 Faults Found:
005659 - Glowplug for Cylinder 2 (Q11)
               P161B - 000 - Open Circuit
             Freeze Frame:
                    Fault Status: 01110000
                    Fault Priority: 0
                    Fault Frequency: 1
                    Reset counter: 255
                    Mileage: 476341 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 01:53:46

             Freeze Frame:
                    RPM: 0 /min
                    Speed: 0.0 km/h
                    Load: 0.0 %
                    Voltage: 11.63 V
                    Bin. Bits: 00001000
                    Temperature: 23.4°C
                    Bin. Bits: 00110000

001026 - EGR System
               P0402 - 000 - Excessive Flow - Intermittent
             Freeze Frame:
                    Fault Status: 00110000
                    Fault Priority: 0
                    Fault Frequency: 254
                    Reset counter: 255
                    Mileage: 476341 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 01:54:51

             Freeze Frame:
                    RPM: 1659 /min
                    Speed: 64.0 km/h
                    Load: 20.0 %
                    Duty Cycle: 100.6 %
                    Duty Cycle: 95.1 %
                    Mass Air / Rev.: 275.0 mg/str
                    Mass Air / Rev.: 0.0 mg/str

000257 - Mass Air Flow Sensor (G70)
               P0101 - 000 - Implausible Signal
             Freeze Frame:
                    Fault Status: 01110000
                    Fault Priority: 0
                    Fault Frequency: 1
                    Reset counter: 255
                    Mileage: 476351 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 02:06:56

             Freeze Frame:
                    RPM: 1932 /min
                    Speed: 91.0 km/h
                    Temperature: 31.5°C
                    Absolute Pres.: 1203.6 mbar
                    Mass Flow: 0.00 g/s
                    (no units): 2.59
                    Temperature: 79.2°C

009236 - Oxygen (Lambda) Sensor B1 S1 Voltage too Low / Air Leakage / Sample Error
               P2414 - 000 -
             Freeze Frame:
                    Fault Status: 01110000
                    Fault Priority: 0
                    Fault Frequency: 1
                    Reset counter: 255
                    Mileage: 478758 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 02:51:32

             Freeze Frame:
                    RPM: 2415 /min
                    Speed: 112.0 km/h
                    Mass Flow: 1.42 g/s
                    Temperature: 36.9°C
                    Absolute Pres.: 969.0 mbar
                    Voltage: 1.095 V
                    (no units): 0.0

001649 - Cylinder 1 Glow Plug Circuit (Q10)
               P0671 - 000 - Electrical Fault - Intermittent
             Freeze Frame:
                    Fault Status: 00110000
                    Fault Priority: 0
                    Fault Frequency: 1
                    Reset counter: 255
                    Mileage: 482986 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 04:18:31

             Freeze Frame:
                    RPM: 777 /min
                    Speed: 0.0 km/h
                    Load: 0.0 %
                    Voltage: 13.30 V
                    Bin. Bits: 00001011
                    Temperature: 27.0°C
                    Bin. Bits: 10110000

012296 - Camshaft Position Sensor (G40)
               P3008 - 000 - Signal Out of Range
             Freeze Frame:
                    Fault Status: 01110000
                    Fault Priority: 0
                    Fault Frequency: 1
                    Reset counter: 255
                    Mileage: 483752 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 06:33:08

             Freeze Frame:
                    RPM: 210 /min
                    Speed: 0.0 km/h
                    Load: 100.0 %
                    Voltage: 10.18 V
                    Bin. Bits: 00001011
                    Idle Stabilization: 0.0°KW
                    (no units): 35.0

Readiness: 1 3 0 0 0

-------------------------------------------------------------------------------
Address 02: Auto Trans        Labels: 02E-927-770.clb
   Part No SW: 02E 300 042 H    HW: 02E 927 770 AD
   Component: GSG DSG         070 0913
   Revision: 04507000    Serial number: 00000510050159
   Coding: 0000020
   Shop #: WSC 00066 000 00000
   VCID: 186E175AAE9F964A579-804C

No fault code found.

-------------------------------------------------------------------------------
Address 03: ABS Brakes        Labels: 1K0-907-379-MK60-F.clb
   Part No SW: 1K0 907 379 Q    HW: 1K0 907 379 Q
   Component: ESP FRONT MK60      0102
   Revision: 00T12001 
   Coding: 0021122
   Shop #: WSC 00066 000 00000
   VCID: 40DE9F3A968FFE8ACF9-8014

No fault code found.

-------------------------------------------------------------------------------
Address 08: Auto HVAC        Labels: 1K0-820-047.lbl
   Part No: 1K0 820 047 DL
   Component: Climatic PQ35   090 0505
   Shop #: WSC 00000 000 00000
   VCID: 71B80AFEEDA52702707-8024

1 Fault Found:
00229 - Refrigerant Pressure
            002 - Lower Limit Exceeded

-------------------------------------------------------------------------------
Address 09: Cent. Elect.        Labels:. 3C0-937-049-23-M.lbl
   Part No SW: 3C0 937 049 D    HW: 3C0 937 049 D
   Component: Bordnetz-SG     H37 1002
   Revision: 00H37000    Serial number: 00000000205599
   Coding: 14018E234004180000140000001400000008730B5C
   Shop #: WSC 23071 444 66570
   VCID: 2A0ADD9200F314DAF1D-807E

   Subsystem 1 - Part No: 1K1 955 119 C  Labels: 1KX-955-119.CLB
   Component: Wischer VW350  012  0402
   Coding: 00063445
   Shop #: WSC 23071

7 Faults Found:
01501 - Bulb for Blinkers; Rear Left (M6)
            012 - Electrical Fault in Circuit - Intermittent
             Freeze Frame:
                    Fault Status: 00101100
                    Fault Priority: 2
                    Fault Frequency: 1
                    Reset counter: 9
                    Mileage: 483645 km
                    Time Indication: 0

             Freeze Frame:
                        ON
                    Voltage: 13.80 V
                        ON
                        ON
                        OFF
                        OFF
                        ON

01505 - Bulb for Blinkers; Rear Right (M8)
            012 - Electrical Fault in Circuit - Intermittent
             Freeze Frame:
                    Fault Status: 00101100
                    Fault Priority: 2
                    Fault Frequency: 1
                    Reset counter: 9
                    Mileage: 483646 km
                    Time Indication: 0

             Freeze Frame:
                        ON
                    Voltage: 13.85 V
                        ON
                        ON
                        OFF
                        OFF
                        ON

01519 - Bulb for Back-Up Lights; Right (M17)
            012 - Electrical Fault in Circuit
             Freeze Frame:
                    Fault Status: 01101100
                    Fault Priority: 2
                    Fault Frequency: 1
                    Reset counter: 228
                    Mileage: 476341 km
                    Time Indication: 0

             Freeze Frame:
                        ON
                    Voltage: 12.55 V
                        ON
                        ON
                        OFF
                        OFF
                        OFF

01495 - Bulb for High-Beams; Left (M30)
            010 - Open or Short to Plus - Intermittent
             Freeze Frame:
                    Fault Status: 00101010
                    Fault Priority: 3
                    Fault Frequency: 34
                    Reset counter: 13
                    Mileage: 476481 km
                    Time Indication: 0

             Freeze Frame:
                        ON
                    Voltage: 11.30 V
                        ON
                        ON
                        OFF
                        OFF
                        OFF

01499 - Bulb for High-Beams; Right (M32)
            010 - Open or Short to Plus - Intermittent
             Freeze Frame:
                    Fault Status: 00101010
                    Fault Priority: 3
                    Fault Frequency: 26
                    Reset counter: 0
                    Mileage: 476481 km
                    Time Indication: 0

             Freeze Frame:
                        ON
                    Voltage: 11.30 V
                        ON
                        ON
                        OFF
                        OFF
                        OFF

00978 - Lamp for Low Beam; Left (M29)
            010 - Open or Short to Plus
             Freeze Frame:
                    Fault Status: 01101010
                    Fault Priority: 1
                    Fault Frequency: 254
                    Reset counter: 228
                    Mileage: 476368 km
                    Time Indication: 0

             Freeze Frame:
                        ON
                    Voltage: 14.25 V
                        ON
                        ON
                        OFF
                        OFF
                        OFF

00979 - Lamp for Low Beam; Right (M31)
            010 - Open or Short to Plus - Intermittent
             Freeze Frame:
                    Fault Status: 00101010
                    Fault Priority: 1
                    Fault Frequency: 221
                    Reset counter: 13
                    Mileage: 476585 km
                    Time Indication: 0

             Freeze Frame:
                        ON
                    Voltage: 14.00 V
                        ON
                        ON
                        OFF
                        OFF
                        OFF


-------------------------------------------------------------------------------
Address 0F: Digital Radio        Labels: 8E0-035-593-XM.lbl
   Part No SW: 8E0 035 593 E    HW: 8E0 035 593 E
   Component: SDAR XM         H03 0080
   Revision: 00000000    Serial number: AUZ4Z7E2040761
   Shop #: WSC 00000 000 00000
   VCID: 2B04D8960F090DD20AB-807E

3 Faults Found:
00003 - Control Module
            014 - Defective
             Freeze Frame:
                    Fault Status: 01101110
                    Fault Priority: 5
                    Fault Frequency: 1
                    Reset counter: 77
                    Mileage: 33835 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 07:02:47

02788 - Internal Communications Error
            000 - - - Intermittent
             Freeze Frame:
                    Fault Status: 00100000
                    Fault Priority: 7
                    Fault Frequency: 254
                    Reset counter: 13
                    Mileage: 476341 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 07:07:42

             Freeze Frame:
                    Bin. Bits: 00000010
                    Bin. Bits: 00000000

01304 - Radio
            008 - Implausible Signal
             Freeze Frame:
                    Fault Status: 01101000
                    Fault Priority: 5
                    Fault Frequency: 1
                    Reset counter: 62
                    Mileage: 476341 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 06:41:49


-------------------------------------------------------------------------------
Address 15: Airbags        Labels: 1K0-909-605.lbl
   Part No SW: 1K0 909 605 P    HW: 1K0 909 605 P
   Component: 38 AIRBAG VW8R  032 6800
   Revision: 02032000    Serial number: 0038FD0285T/
   Coding: 0013112
   Shop #: WSC 00066 000 00000
   VCID: 3928F2DEF555AF42887-806C

   Subsystem 1 - Part No: 1K0 959 339 E
   Component: BF-Gewichtsens. 006 0005

   Subsystem 2 - Serial number: 6332MSME0C0E7568N

   Subsystem 3 - Serial number: 6342MSME0C2444053

   Subsystem 4 - Serial number: 6351HSME085C0C61B

   Subsystem 5 - Serial number: 6361HSME085C231BA

   Subsystem 6 - Serial number: 63727SME08315A760

   Subsystem 7 - Serial number: 63827SME083706780

1 Fault Found:
01639 - Crash-Sensor for Side Airbag; Rear Passenger Side (G257)
            014 - Defective - Intermittent - MIL ON

-------------------------------------------------------------------------------
Address 16: Steering wheel        Labels: 1K0-953-549-MY8.lbl
   Part No SW: 1K0 953 549 AH    HW: 1K0 953 549 AH
   Component: J0527           034 0070
   Coding: 0010021
   Shop #: WSC 00066 000 00000
   VCID: 78AE37DA8EDF764AB79-802C

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments        Labels: 1K0-920-xxx-17.lbl
   Part No: 1K0 920 952 D
   Component: KOMBIINSTRUMENT 3HL 1212
   Coding: 0023203
   Shop #: WSC 23071 067 57207
   VCID: 2B04D8960F090DD20AB-807E

No fault code found.

-------------------------------------------------------------------------------
Address 19: CAN Gateway        Labels:. 1K0-907-530-V1.clb
   Part No SW: 1K0 907 530 F    HW: 1K0 907 951
   Component: Gateway         H10 0120
   Revision:   H10       Serial number: 2800105A0285EB
   Coding: 3F3F0B60071002
   Shop #: WSC 00066 000 00000
   VCID: 2A0ADD9200F314DAF1D-807E

1 Fault Found:
01304 - Radio
            004 - No Signal/Communication
             Freeze Frame:
                    Fault Status: 01100100
                    Fault Priority: 2
                    Fault Frequency: 254
                    Reset counter: 228
                    Mileage: 476341 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 06:41:53


-------------------------------------------------------------------------------
Address 25: Immobilizer        Labels: 1K0-920-xxx-25.clb
   Part No: 1K0 920 952 D
   Component: IMMO            3HL 1212
   Shop #: WSC 00000 000 00000
   VCID: 2B04D8960F090DD20AB-807E

No fault code found.

-------------------------------------------------------------------------------
Address 42: Door Elect, Driver        Labels: 1K0-959-701-MIN2.lbl
   Part No: 1K0 959 701 K
   Component: Tuer-SG         024 2377
   Coding: 0001269
   Shop #: WSC 00066 000 00000
   VCID: 3632F9E2C44B403A655-8062

No fault code found.

-------------------------------------------------------------------------------
Address 44: Steering Assist        Labels: 1Kx-909-144-G2V2.clb
   Part No: 1K1 909 144 J
   Component: EPS_ZFLS Kl.5   D04 1606
   Shop #: WSC 00000 000 00000
   VCID: 323AC5F228235C1A49D-8066

No fault code found.

-------------------------------------------------------------------------------
Address 46: Central Conv.        Labels:. 1K0-959-433-MIN.clb
   Part No: 1K0 959 433 AF
   Component:    KSG              0401
   Coding: 137803281B09058F880F048051A0
   Shop #: WSC 00066 000 00000
   VCID: 74B603EA92B7122A9B1-8020

   Subsystem 1 - Component:   Sounder n.mounted   

   Subsystem 2 - Component:       NGS n.mounted   

   Subsystem 3 - Component:      IRUE n.mounted   

1 Fault Found:
00930 - Locking Module for Central Locking; Rear Left (F222)
            012 - Electrical Fault in Circuit - Intermittent

-------------------------------------------------------------------------------
Address 52: Door Elect, Pass.        Labels: 1K0-959-702-MIN2.lbl
   Part No: 1K0 959 702 K
   Component: Tuer-SG         024 2377
   Coding: 0001269
   Shop #: WSC 00066 000 00000
   VCID: 372CF4E6C341B9327E3-8062

3 Faults Found:
01553 - Motor for Central Locking; Passenger Door (V57); Lock
            012 - Electrical Fault in Circuit
00929 - Locking Module for Central Locking; Front Passenger Side (F221)
            008 - Implausible Signal
00121 - Outside Warning Light/Door exit Light Passenger Side
            012 - Electrical Fault in Circuit

-------------------------------------------------------------------------------
Address 56: Radio
Cannot be reached

-------------------------------------------------------------------------------
Address 62: Door, Rear Left        Labels: 1K0-959-703-GEN2.lbl
   Part No: 1K0 959 703 D
   Component: Tuer-SG         021 2434
   Coding: 0000144
   Shop #: WSC 00066 000 00000
   VCID: 3138CAFE2D256702307-8064

No fault code found.

-------------------------------------------------------------------------------
Address 72: Door, Rear Right        Labels: 1K0-959-704-GEN2.lbl
   Part No: 1K0 959 704 D
   Component: Tuer-SG         021 2434
   Coding: 0000144
   Shop #: WSC 00066 000 00000
   VCID: 323AC5F228235C1A49D-8066

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: 2D00D68E311D03E214F-8078

1 Fault Found:
00361 - Heater Element for Auxiliary Heater (Z35)
            014 - Defective

End----------(Elapsed Time: 01:14, VBatt start/end: 12.1V/12.1V)-----------
------------------------------24 Faults Found------------------------------

 

[beowulf_lives]

Is it correct that there's two relays?

There are two fuel pump relays called J17 (449 on top) at position 2/2 under the dash which supplies the fuel pressurization pump in the tank and Fuel Pump 2 Relay (J49) (449 on top) at position 1/1 under the dash which is Fuel Pump 2 Relay (J49) and supplies fuel pump 2 in the engine bay. Both relays are part number 1K0 951 253 and cost about £11 from a VW dealer.

 

[Rx7145]

Tach comes up when cracking?
take the filter top off and have someone cycle the key, fuel come out?
take the glow plugs out and see if you get puffs of fuel coming out.

 

[beowulf_lives]

The tach does come up when cranking.

I just got the vehicle home, so I'll have answers to the other two questions by tomorrow.
Two new 449 J17 relays are on order. I'm sure the current ones are original.

 

[beowulf_lives]

Fuel is entering the filter housing. I’m not seeing or smelling fuel enter the cylinders. I removed two glow plugs and nothing.

 

[325_Guy]

The fuel pump dying shouldn't have caused the engine to quit while running, as the tandem pump can draw fuel on its own.

I'm wondering if the camshaft position sensor is sending implausible data to the ECM that's causing your no-start.

If the ECM doesn't have a valid CPS signal, it can use the crankshaft position sensor to derive cylinder position in order to control injector firing.

You could try unplugging the CPS and see if the engine will start.

 

[oilhammer]

The fuel pump dying shouldn't have caused the engine to quit while running, as the tandem pump can draw fuel on its own.

The dozens of PDs I've had come in on a tow truck with dead lift pumps would suggest otherwise. But either way, this is a quick 10 second test, they either work or they don't.

 

[Vince Waldon]

Yup, some early versions of the in-tank pump/sender would allow a bypass when the lift pump failed but most have long since been replaced with the "revised" design that won't (and thus leaves you at the mercy of the tow truck).

Have had one of each...hunted all over for NOS of the original design but no luck.

 

[beowulf_lives]

I thought I had answered that the lift pump was working. When the engine is cranked fuel enters the fuel filter canister. To be fair I didn’t mention that I first removed the cover off the fuel filter and placed over oil catch pan. It’s weird that I couldn’t hear it prime though.

The tandem pump is leaking some so it’s getting replaced. The cam sensor will get replaced as part of doing the timing belt. New lift pump as well.

That’s the plan for this week!

Edit: sorry, yes I see above I said it was entering the fuel filter canister. Not accurate. The test was done with the fuel filter lid off.

 

[beowulf_lives]

Lift pump: https://cascadegerman.com/product/fuel-pump-mk5-mk6-tdi-bosch/


tandem: https://cascadegerman.com/product/038145209q/ NAPA wanted $750 USD for this and no returns!

timing kit: https://cascadegerman.com/product/038198119std-brm/

Cam sensor was also cascade German.

 

[325_Guy]

The dozens of PDs I've had come in on a tow truck with dead lift pumps would suggest otherwise. But either way, this is a quick 10 second test, they either work or they don't.

Yup, some early versions of the in-tank pump/sender would allow a bypass when the lift pump failed but most have long since been replaced with the "revised" design that won't (and thus leaves you at the mercy of the tow truck).

Have had one of each...hunted all over for NOS of the original design but no luck.

@oilhammer, I don't doubt your experience at all. But, I knew I wasn't remembering wrong! My Mk5 journey began in 2011 and I knew I had read somewhere back then that the tandem pump could still pull fuel even with an inop lift pump.

@beowulf_lives, for what it's worth I'm still wondering if the issue is your camshaft sensor. My daily driver Mk5 is just shy of 490,000 miles on the original lift pump and tandem pump.

 

[beowulf_lives]

@325_Guy My initial assumption was the tandem pump fed the injectors through the cylinder head where they mated together. Having replaced the tandem pump I now realize, like you said, their was nothing wrong with the original one. I'm hopeful the only issue is the camshaft sensor. The tandem pump was only $250 USD and wasn't hard to replace and I learned something. The existing lift pump pushes fuel fine, too.

Yet to see fuel enter the cylinder but that could just have been late night user error. Engine bay is too torn apart to check again.

The timing belt, water pump, ancillaries and the cam sensor will be replaced this weekend. I've done it once before on a GLS and I really don't want to do it again!

Thank you all for the help, I'll update how it all goes.

 

[beowulf_lives]

On a related note, I've been looking at buying a picoscope. It looks to be a good scanner to learn on.

 

[beowulf_lives]

Hi all, did the timing belt, water pump, and camshaft sensor yesterday. I’d say all the symptoms mentioned were related to the timing belt missing so many teeth. I got really lucky.

IMG_3879.jpeg

• beowulf_lives
• Sep 15, 2025

IMG_3878.jpeg

• beowulf_lives
• Sep 15, 2025

 

[beowulf_lives]

The experience was a lot and I really don’t want to relate all of it but …

Replaced the timing belt, tensioner, roller, cam sensor, water pump, and the serpentine belt. New coolant, oil, and fresh oil and fuel filters. $300

Replaced the ‘wasn’t broken to begin with’ tandem pump too. $200

Manually turned the motor over twice by hand. Good.

Put everything back together and triple checked everything. pulled vacuum on the fuel return line the way it’s shown in All Data. 30 seconds of cranking and it fired.

You’re all a good bunch and I’ve really appreciated the advice!

 

[beowulf_lives]

Will do a compression test next weekend but it drives as well as it did.

Took a hard look at the cam lobes. Which ever the lobe is farthest over to the driver side (N America) is very worn. The other exhaust lobes are worn but not to the same degree.

That will be the next job!

 

[325_Guy]

Wow. Would not have expected that at all based on the symptoms described.

With the timing belt in that condition and the fact that it died while driving, it is almost without doubt that the camshaft and crankshaft went out of time while the engine was at operating speed.

On our TDI engines, that means certain piston to valve contact.

Since the valves travel vertically in relation to the piston, when there's piston to valve contact three things occur:
Valve stems compress
Lifters bulge upward (dome)
Rods can bend

Since the valves still seal, often times a timing belt replacement (like you did) will get things going again.

In about 10,000 miles or so (maybe more maybe less), one or more of those valves will break off at the head-to-stem junction, drop into the cylinder, and from there destroy the engine.

When you took everything apart, did you lock / index the crankshaft and camshaft at TDC? Or were they already out of time?

I would pull the valve cover and inspect the lifters for evidence of cracking and upward doming. And then plan for the head to come off.

 

[325_Guy]

Thinking further, if the stripped teeth portion of the timing belt was on the crankshaft gear, I bet the camshaft wasn't even turning. Which would explain both the apparently inoperative tandem pump and the lack of fuel injection to the cylinders.

 

[beowulf_lives]

For sure, both top and bottom were indexed with the correct tools. The camshaft pin was slotted all the way into that very precise pin hole. Likewise the crank was held correctly too.

Will look more next weekend but if there was contact surely he’d have heard it.

where does this 10k mile number come from?

much thanks

 

[privateTDIjet]

Hi all, did the timing belt, water pump, and camshaft sensor yesterday. I’d say all the symptoms mentioned were related to the timing belt missing so many teeth. I got really lucky.

IMG_3879.jpeg

• beowulf_lives
• Sep 15, 2025

IMG_3878.jpeg

• beowulf_lives
• Sep 15, 2025

Woah!
Your car is at 483750km / 300588miles.. when was the last timing belt change??

 

[Rx7145]

Is it possible that your Cam lobes were so worn that the valves didn’t hit the pistons? I’m not even sure if such a thing is possible but I’m shocked there wasn’t catastrophic damage.

 

[325_Guy]

For sure, both top and bottom were indexed with the correct tools. The camshaft pin was slotted all the way into that very precise pin hole. Likewise the crank was held correctly too.

Before removing the old belt, or when installing the new one?

When you pulled the old belt, where was the section of stripped teeth?

Will look more next weekend but if there was contact surely he’d have heard it.

Not necessarily. It’s not noisy. And usually people dealing with sudden engine failures are more worried about getting off the road than they are about listening for engine noises.

where does this 10k mile number come from?

It’s just a ballpark range, from decades of experience. The concept of TDI engines isn’t new, and the failure modes are known. Essentially at this point you have a time bomb, and at any point between now and the next few thousand miles a valve will break off, drop into the cylinder, and destroy both the block and the head.

All that said, I am sorry to be the bearer of bad news.

 

[P2B]

Essentially at this point you have a time bomb, and at any point between now and the next few thousand miles a valve will break off, drop into the cylinder, and destroy both the block and the head.

All that said, I am sorry to be the bearer of bad news.

Conventional wisdom around here says that engine will inevitably be destroyed by a dropped valve head at some point, and certainly there have been many documented cases over the years - but I wonder if there are cases we don't hear about, where the owner actually got away with just replacing the timing belt

 

[beowulf_lives]

Hi all

My apologies I've been quite busy with work.
Tonight I'll pull the cam cover and take another look.

I'm kinda live streaming my thoughts here but I'm noticing the price of BRMs are dropping, probably correlated to the change in seasons. I'm a 'fix the broken thing' kinda guy but I think it's better to buy another with less mileage over rebuilding the top-end. Note thath VCDS list in the first post.

Should I buy another or switch to the MK6? I think we agree the MK6 looks better, but putting aside my mistakes with this car I know the Mk5 BRM pretty well. The gas mileage never gets old, car insurance is cheap, and it's extremely reliable.

 

[325_Guy]

I think we agree the MK6 looks better

Disagree.

 

[325_Guy]

As for your Mk5, could always find a spare engine and wait for the inevitable. Maybe it will take some time to pass.

 

[privateTDIjet]

Hi all

My apologies I've been quite busy with work.
Tonight I'll pull the cam cover and take another look.

I'm kinda live streaming my thoughts here but I'm noticing the price of BRMs are dropping, probably correlated to the change in seasons. I'm a 'fix the broken thing' kinda guy but I think it's better to buy another with less mileage over rebuilding the top-end. Note thath VCDS list in the first post.

Should I buy another or switch to the MK6? I think we agree the MK6 looks better, but putting aside my mistakes with this car I know the Mk5 BRM pretty well. The gas mileage never gets old, car insurance is cheap, and it's extremely reliable.

I used to think the same that the mk6 is better looking but then realized once you strip the MK5 of all its chrome and big headlights, it looks (personally) a lot nicer than the mk6. Same for the interior, I dislike the hollow feel of the MK6.

You should just look at this engine wise. 2009+ cars have HPFP risks and annoying emissions systems... not to mention the oil pump shaft with the 2009.

The only problem that comes to my mind with the 2006 BRM is the camshaft eventually eating itself out. That and probably rust, this being an older car. You'll have the change the flywheel on both too.

 

[325_Guy]

Same for the interior, I dislike the hollow feel of the MK6.

IIRC, VW essentially stripped down the Mk6 interiors as they realized they were spending more than they liked on the Mk5's features.

There's other places the Mk6 went "backwards" from the Mk5...straight beam rear axles, for one, versus the Mk5 independent rear.

You should just look at this engine wise. 2009+ cars have HPFP risks and annoying emissions systems... not to mention the oil pump shaft with the 2009.

This is a good point also. The BRM may need a couple of camshafts in its service life but it also only needs a working crankshaft position sensor to run. It's not an ALH but it's a lot less complex than the TDIs that came after it.

 

[Rx7145]

Mk6 went backwards for a hood prop, trunk hinges, and no power outlet in the trunk.