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It is absolutely galling how it cost you 3k to effect repairs that could have been almost totally averted by this 1-2 minute computer adjustment procedure.!!!!
Do a search on the TDICLUB.com under TDIFAQ,...MAINTENANCE...Intake Manifold and EGR Cleaning,... Avoiding the Need for Intake Manifold Cleaning - Recalibrating the EGR System....
It should explain the procedures et all, in pretty good detail. This is like one of two suicide or self destruct features on the VW and TDI. The other is the possibility of catastrophic failure in case of timing belt failure.
BTW, crappy diesel is responsible for the EGR buildup. The EGR system is in place for emissions reasons, but if left operating and used in conjunction with crappy diesel it will plug-up quickly. I don't think this is mentioned anywhere in the manual as a maintenance issue, it's something the average consumer has to figure out on their own. I don't have any build-up in my EGR but I've taken precautions to assure this.
City driving also encourages the EGR to activate (if it's not disabled) so a lot of city driving can increase the gunk inside the intake.
I generally run a premium diesel (BP Supreme) which is much cleaner than your average diesel. Engine runs quieter/smoother as well. Biodiesel is also another good way to ensure a clean intake. Users of B-20 (20% biodiesel, 80% diesel) report cleaner intakes as well.
I have a '99 Jetta GLX vr6 w/34k, and I'm getting a little fed up with its problems.
I'm interested in the RSX-S, Golf TDI, and WRX. Any suggestions? I've read some of your problems, and that all seems manageable compared to my Jetta.
What do you think? I'd appreciate it.
JBkreegs
This is one reason that VW specifies using only SYNTHETIC oil that meets the VW505.1 specification. (This oil is INTENDED for use in a 'cooled EGR' diesel engine.)
ADDITIONALLY: Driving the TDI engine gingerly or "babying" it will also tend to plug up the intake and the turbocharger. A diesel engine needs to be run HARD once in a while to keep things cleaned out. This can be accomplished by brisk acceleration once in a while. You may get a cloud of black smoke... this shows that you are cleaning out the soot from the turbocharger.
Of course, I applied the "EGR mod" to my TDI at 3000 miles because I 'did my homework' and researched for many months before purchasing.
I recently replaced the EGR valve in my 83 Mercedes 300 SD (5 cylinder turbodiesel). I bought the new EGR valve for $ 100. It is a genuine Mercedes replacement part, but from an aftermarket company. I absolutely cannot believe that it would cost $ 3000 to repair clogged EGR passages on a Jetta TDI. I bet I could get my Mercedes engine rebuilt for $ 3000 (not that it needs it).
I have never heard of the EGR system itself getting cloged on the TDI. If this were to happen then the intake manifold would not plug up because one of the 2 factors leading to intake clogging would be missing. (But a 'check engine' light (CEL) would be flagged)
In fact, the "EGR MOD" does EXACTLY this very thing -- it cuts off the EGR function to the bare minimum. (just above the point of throwing a CEL)
It PURPOSELY "pluggs up" the EGR using the computer programming.
Do not forget that EGR is for emmissions only... recirculating the exhaust gasses back into the engine has NEVER been 'good' for an engine.
I guess that's the new "baby tiptronic" for the transverse engines? I believe the Passat (with the longitudinal engine) gets the same tiptronic tranny as the A-8 and Phaeton. I'm not sure if that's really better, but it is designed to handle more power. Not an issue with a Jetta TDI!
Power is an issue with the new Jetta TDI. It has 177 lb/ft of torque, more than the 1.8T.
for 2004
2004 Golf, Jetta and New Beetle GL and GLS trim levels will have a new 1.9L TDI-PD with 100hp and 177 lb-ft. of torque available in GL and GLS trim levels. The Golf and Jetta models will be available with a choice of a 5-speed manual or 5-speed tiptronic transmission.
This car would be a daily driver, but noise and smoke are not a problem (highly desirable, in fact).
This will be an interim vehicle while I save up for a full size diesel pickup, so I don't want to spend too much money on it, but I want it to be enjoyable to drive while I've got it.
I was a diesel mechanic in a past life, so I'm able to work on it myself, but I'm not real familiar with the particulars of VW's.
Chip => http://www.upsolute.com/
Injectors => http://www.kermatdi.com/
Gauges => http://www.42draftdesigns.com/
Intercooler pipes => http://www.dieselgeek.com/
BTW --- the MPG has been reported to IMPROVE with the above modifications with daily driving - (until you get heavy on the throttle)
I take it someone sells an aftermarket clutch that can take the torque?
I also understand that there is now an aftermarket clutch available that can handle the increased torque.
Do not forget that one reason that the clutch on the stock Jetta is so nice to drive is because it is a "dual density" friction plate design... apparently there are not many aftermarket parts available for this.
BTW: By federal law, all emmissions equipment is covered by the "Federal Emmissions Warantee" for 10 years/100,0000 miles on a 2000 model.
As for the glow plugs, they don't even operate until much colder temps. My glow-plug harness died on me this spring, and I just got around to fixing it recently. Doesn't matter a bit if the glow-plugs work in the summer. I think 45F is about the point they start becoming necessary.
Never heard of the brake problem. I'm at 70k miles on factory pads with no issues.
What is this "emissions valve" and how much did they charge for it? Was it an EGR valve? Why did it need replaced?
GL 5-speed manual: 18,670
GL 5-speed tiptronic: 19,745
GLS 5-speed manual: 20,480
GLS 5 speed tiptronic 21,555
Monsoon is standard on 2003 GLS. Cold weather pkg not available on 2004 GL.
Are you getting excessive smoke and less than 50MPG? (these are signs of mis-adjusted injection timing)
There is a "master" injection timing setting that is set by physically adjusting the injection pump.
There is also "electronic" timing settings that can be checked/adjusted using a laptop computer.
Many folks with starting issues have reported that after having the above injection timing(s) properly set up... their TDI starts quicker than a GASSER...even at cold temps.
Sorry I cannot help you any further with this.
I have never had a starting problem... my TDI fires up with a touch of the key at all temps. (I have checked my Injection Timing with laptop though)
I suggest you spend some time in the TDIFAQ it is full of great information. (and has an extensive section on hard starting and how to check/adjust the above injection timings with laptop computer)
The very best source of TDI knowledge is fellow TDI owners that are willing to hook up their laptop to your TDI and are skilled at setting up all of the slick features. I was lucky enough to locate a fellow TDI owner near me to help set up my EGR settings using a laptop to eliminate the dreaded "clogged intake manifold" issue.
Let us know how this works out for you.
I specifically orderd my 2003 GLS without the 'monsoon' and it STILL sounds better than my sisters fancy BMW system. In my opinion, the 'monsoon' is not worth the xtra $$ over the 'standard' system which is VERY good.
My opinion is that the Monsoon system is worth the extra $325 on the 2003 and 2002. I have it on my 2002 Golf and my previous Golf did not have it. Much, much better than the standard system. The standard system is quite good in my opinion.
If the diagnostics for VAGCOM were not tied into the head unit I would say forget about Monsoon and go aftermarket.
I can not wait to try out the 2004 TDI with 177lb/ft of torque.
Also, I heard that the Passat TDI may actually start showing up in December, which was the original expected time. That would be very nice.
So the dealers are expecting them in Feb. or March (based on VWs past performance)
In the NH winter, the light may stay on for upwards of 10 seconds, but the car will start fairly easily once the light goes out. (this patience in key turning takes some getting used to for a lifelong gasser!).
It is a 2002 Jetta TDi with 18K on it. I average 1K per month, with a daily short commute at 45 mph max, 30 min. ( minus starting and stopping of course). When I head into the big city, I do 20 miles at highway speed (80 or so).
The questions are: Am I headed for EGR problems with this type of driving? Does my description sound like a glow plug issue?
Thanks in advance!
why is the light on? It ALWAYS comes on to indicate glowplug operation then the computer turnes it off based on engine temperture. (colder temps= longer "on time")
Am I headed for EGR problems with this type of driving? It is not the ROAD speed you drive that may affect the EGR... it is more related to ENGINE speed and loading. (Of course, we assume you HAVE performed the "EGR mod"... otheweise the answrver is a unequivical YES!)
Does my description sound like a glow plug issue? I have read your append several times and see no "issue" you are describing. What am I missing here?
If you are experiencing "hard starting" have your IQ checked (Injection Quality)
The TDI should start like a gasser with no hesitation whatsoever at any temp above 40F.
(DNS=Domain Name Server)
If you have this problem with both doors, then it's more likely a fuse.
The AC is the way it is designed and not a problem per se, the lint problem with the cloth is an annoyance and one I did not have a big problem with (my clothes must not be as linty as others). The rest of your items indicate a lemon.
What type of driving conditions does the car endure? The Al-Can highway?
I do want to mention the following.
*)Stalling in cold weather is most likely gelling of the fuel. To alleviate this, ALWAYS use a fuel additive.
*)squeaking brakes and 'flexing sounds' should not be construed as problems.
*)Key sticking in ignition is normal when the steering lock is 'pegged'. Virtually ALL vehicles do this.
*)The "linting" seats is a known issue, better research before buying would have steered you clear of this. (It did I)
*)A/C - Why is this an issue? Does it not get cold? Who wants it BLOWING on them anyway? That is uncomfortable. A good climate-control system will maintain the envronment... not BLOW on people.
*)40MPG with automatic is not abnormal. (adjusting the IQ may help.)
*) Cupped tire is covered by separate tire warantee. (It is a defect) besides... you cant blame VW for this.
*)Dome light... warantee item (whats the big deal?)
Considering that you feel these are 'unreasonable' issues, perhaps you would be happier with somthing else. Beware,ALL vehicles have issues. If your dealer treats you reasonably well you are lucky.
If you wish to KEEP your TDI, I recommend that you consider the "EGR mod" to eliminate intake plugging. I assume you ARE using the proper synthetic oil in the engine.
thanks.
Then I read this forum and other Volkwagon forum and cam e to the conculsion that VWs are bascially unrelaible unless you get a quirk and then iti s relaible. New VW owners brag about going thousands of miles without being stranded and think that is good.
I didn't buy one and I am glad. I couldn't put up with all of the realiaiblity problems and other minor things like windows falling out.
VW and TDI unreliable? Not in my experience.
Do VW's have more problems than the average as observed by JD Power? They certainly do.
In over 600,000 miles of driving I've yet to be stranded by any make of vehicle for a mechanical problem other than one time a fuel gauge on a Toyota was broke and I ran out of fuel.
It's amazing what proper maintenance and proper operation can do for vehicle reliability.
However, having to mod a brand new car (EGR), add the cetane to the fuel and all the other crap you have to put up with due to our lousy fuel in the good ol USA is not acceptable for a new car. Period.
I bought a Focus ZTW loaded and like it.
I'll wait for the good diesel and the better engines in a few years. Don't get me wrong, those who "take care" of their TDIs have educated us curious masses well, but, well I'd rather go to the beach...
In any case.. I, for one, was VERY willing to get 600+ miles per tankful of fuel. After spending over $30 USD a week in my V8 truck... the TDI has been a blessing.
Now I spend $30 a MONTH and drive a lot more to boot! (The truck is relagated to 4X4 duties and taking trash/recycleables to the xfer station.)
Then, just this week, on a foggy morning with similar temperature (just coincidence?), the exact same thing happened. This time I was 75 miles from home, so I had the car towed to the nearest dealer. There, it sat for 2 days before they even looked at it (arrrrg). When they did try to drive it, they saw nothing of the intense power loss that I experienced. They said that "nothing is wrong now".
One thing I noticed though, is that in both cases the car would take alot of cranks to finally start in the days preceeding the main power loss.
When I pick up the car, I plan to question them with regards to:
- Condition of EGR Valve, MAF sensor,
- Status of chip settings
- Cleanliness of the cooer and intake manifold
Anybody have any similar experiences?
Did the current dealer check all the codes or just drive it around and say it was fine?? If there were some codes set, that would at least give you a hint. It will be hard to diagnose if the problem isn't present while they're working on it. I would also sign up as a member for www.tdiclub.com as there is huge amounts of info and members more knowledgeable than many vw mechanics.
The New Beetle TDI will have DSG 6 speed auto as transmission option though it is not yet available. That will be an interesting combination.
I've been waiting to buy a car since last June. I initially intended to buy the 2004 Toyota Prius, but decided on the VW.
My last car was an '87 Subaru GL, so this is definitely a step up in terms of style, comfort and power.
So far I've gotten 50 miles to the gallon. This is mostly highway driving.
It drives smoothly, especially the stearing.
The sound system cranks (a plus for a musician)and did I say I got 50 miles to the gallon?!
Plus, I have the option of using biodiesel.
I don't see why anyone would want to buy a car that gets less than 40 miles to the gallon since there are cars out there that are way more efficient.
Hopefully I'll feel this way in the long term. I'll try to post comment occasionally.
If you have any specific questions, I'd be happy to try to answer them.
Garrett