2004 Volkswagen Jetta: engine failure

Filed Oct 6, 2010 · Engine, Transmission · 105,000 miles · TN

Catastrophic drive train failure of a vw jetta tdi 5-speed. While traveling at 65-70 MPH on relatively flat terrain on a clear roadway in 5th gear with no input to the clutch or the transmission, occupants felt & heard a single, muffled 'thump'. Originating drive train failure event occurred spontaneously and completely unexpectedly. After the anomaly, a low metallic rattle was heard. Once clear of surrounding traffic, in troubleshooting attempt the driver engaged clutch and shifted into neutral; immediately the rattling became more pronounced. Fifth gear immediately reengaged and noise abated. Driver navigated vehicle under power to right lane & subsequently exited expressway. Upon approach to side street traffic light, the clutch was reengaged resulting in a renewed rattling; transmission shifted into neutral. When clutch was let out, the constant rattling noise continued as engine idled. With signal change, clutch reengaged & transmission shifted to 1st gear. Clutch slowly, carefully released: noticeable noise increase followed by short series of loud, sharp noises. Vehicle lurched and stalled. Two attempts to restart engine failed; no engine response. Police notified & vehicle towed to dealer. Significant fluid leakage noticed. Subsequently notified by vw dealer that main shaft of transmission catastrophically failed pressing flywheel into motor damaging casing, bearings & crankshaft lobs resulting in immediate seizing of the diesel power plant. Total replacement of transmission and engine assembly required (est ~$11k). This vehicle had all maintenance service performed regularly at 5k intervals by vw dealer (documented) and had recently had full 100k service including timing belt replacement. No notification/concern for additional transmission inspection/service. Clutch recently seemed to be engaging a wee bit further but no bottoming of pedal or clutch slippage. Owner expected to schedule clutch inspection/work during next 5k service visit.

Filed Apr 29, 2010 · Engine · TX

Letter from congressman carter on behalf of constituent regarding a situation involving his vw jetta recall announcement (dot/I # 2010-2106) *tgw on january 18, 2010 the consumer took his vehicle to the dealer because of a recall received, however the dealer stated nothing could be done since the check engine light was not on. Six days later, the engine failed while the consumer was more than 450 miles away from home. The consumer had the vehicle towed to repair shop and the service was completed. The consumer then submitted a claim for reimbursement once he returned home, but to date has not received a response from vw.

Filed Jan 5, 2009 · Engine · 148,000 miles · IN

I have a 2004 volkswagen jetta tdi diesel, which has the pd type engine. This pd design has a well-known defect; specifically, an extra load is placed on the camshaft because it drives the fuel injection system, as opposed to previous vw tdi models in which an external rotary pump drove the fuel injectors. Because of this defect, vw instituted a special oil requirement for this car to satisfy the additional lubrication demands of this design. Initially that oil specification was vw 505.01; most recently it has been changed to vw 507 or castrol oe professional 5w/30. I bought this car used with 80,000 miles on it in july, 2006, and have always had my oil changes done at vw dealerships: one in merrillville, in and one in bensenville, il. On all but one occasion, both dealerships documented the use of vw 505.01 compliant oil in my car. On the one occasion in which vw 505.01 oil was not used, the dealer in bensenville, il put a generic oil in my car that had no identifying characteristics, other than its dramatically lower price per quart. I did not notice this at the time, because at this february 23, 2008 service the dealer had also pointed out that I needed to have all 4 brake rotors and pads replaced, so I did not have a lower service cost to alert me; this service cost far more than usual and I did not realize at the time that I could tell exactly what oil they were putting in my car from the part number on my invoice; I thought that part number corresponded to the oil change service itself. On august 8, 2008, I had a catastrophic engine failure of the sort the vw service manual warns about if the wrong oil is used, "...even if only a small amount of incorrect oil is added to the correct oil to top off the level." I did not have an accident, and there were no other cars around me when the failure occurred, but I incurred about $8,000 of repair costs due to damage to my camshaft, valve lifters, total egr-intake system and turbocharger.

Filed Apr 10, 2006 · Engine · 47,000 miles · CA

Developed large internal coolant leak @ ~47,000 miles. This is probably due to internal failure of the egr cooler. Dealer cannot id problem, but this appears to be widespread with this engine. This could result in engine failure and accident.

Filed Mar 27, 2006 · Fuel system · 46,006 miles · VA

Was driving along after just accelerating from a stop light and got up to speed (about 45 MPH). Then I felt what I thought was the engine falter, and the motor just quit, no warning whatsoever. No odd sounds either. Just like I turned the key "off". I coasted to a stop off the road and tried to start it a few times. Just continuous cranking and not even a "cough". No unusual noises, compression seemed good. Timing belt failure appears to be ruled out. No external leak in the fuel pump (the one in the engine compartment) either. When the key is turned on, all the normal dash lights light. Yesterday, I did notice a more pronounced sound coming from the in-tank lift pump when I turned the key to "glow". After the engine failure tonight, I could not hear any sound from the lift pump. Car was towed to the vw dealer since the warranty was still in effect. Today (three days later) the dealer called me and said the in-tank fuel pump failed and it would be replaced under warranty.