Volkswagon TDI
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Posting Guru
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From: Boston, MA
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Regarding Passat TDI's (03-05), there's a ticking time bomb in the balance shaft chain system, it's the automatic adjuster/follower. They have a history of failure 60k-80K. The oil pump is driven off this chain. The upgraded system is gear driven (a VW service upgrade) that costs north of $2500 (including labor).
Glad I had mine done as it was shot when pulled at 90k. Amazingly the chain didn't pop off the gears or the motor would have been toast.
TDIClub Forums - Powered by vBulletin
Regarding Passat TDI's (03-05), there's a ticking time bomb in the balance shaft chain system, it's the automatic adjuster/follower. They have a history of failure 60k-80K. The oil pump is driven off this chain. The upgraded system is gear driven (a VW service upgrade) that costs north of $2500 (including labor).
Glad I had mine done as it was shot when pulled at 90k. Amazingly the chain didn't pop off the gears or the motor would have been toast.
Strokin Okie
Joined: Apr 2004
Posts: 1,883
Likes: 21
From: Oklahoma
I have a 2004 TDI Jetta BEW. I bought it new in 04 and have 176,000 mi on it. I range from 38-42 mpg but usually closer to 42.
I just performed my second timing belt change and went ahead and changed out my cam and followers this time due to premature wear on the exhaust lobes. Overall it wasn't too bad of a job. It runs like a sewing machine.
Besides my 06 PSD CC FX4, it has been the best vehicle I have owned.
I just wish we had a dealership that was worth a back flip!!
I just performed my second timing belt change and went ahead and changed out my cam and followers this time due to premature wear on the exhaust lobes. Overall it wasn't too bad of a job. It runs like a sewing machine.
Besides my 06 PSD CC FX4, it has been the best vehicle I have owned.
I just wish we had a dealership that was worth a back flip!!
Posting Guru
Joined: Dec 2004
Posts: 1,102
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From: Virginia - SW (Riner)
The timing system is one of the few weak spots on the TDI. (VW's in general - the 2.0 gasser's timing belt is also a known prob) One other is the front strut mounts - our Jetta is on its 2nd set of strut mounts @ 160k. The OEM ones were gone @ 90k - got 70 so far on the replacements.
Strokin Okie
Joined: Apr 2004
Posts: 1,883
Likes: 21
From: Oklahoma
The timing system is one of the few weak spots on the TDI. (VW's in general - the 2.0 gasser's timing belt is also a known prob) One other is the front strut mounts - our Jetta is on its 2nd set of strut mounts @ 160k. The OEM ones were gone @ 90k - got 70 so far on the replacements.
Posting Guru
Joined: Dec 2004
Posts: 1,102
Likes: 3
From: Virginia - SW (Riner)
The interval for changing the timing belt seems to vary depending on who you ask. Some say change it @ 80K others say you're ok till 100k - did find that VW has 2 different p/n's for the timing "kit" - they made changes in 03-04 that extended the life out to 120k. Found this out on the VW forum but when I asked a dealer about the 2 pn's they said their was only one and it should be changed. @ 75k. I ended up getting the parts online and doing it myself - changed to the metal impeller WP at the same time.
Posting Guru
Joined: Dec 2004
Posts: 1,102
Likes: 3
From: Virginia - SW (Riner)
There's also 2 pn's for the older models - VW made an "upgrade" so they'd last longer. Anyone with an older TDI should upgrade to the new pn so it won't have to be changed out as often
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Posting Guru
Joined: Dec 2004
Posts: 1,102
Likes: 3
From: Virginia - SW (Riner)
Its been a couple of yrs since I did it but I recall something about the tensioner is different too. This was well covered ovr in the the VW forum.
Glad we don't have to deal with this kinda thing on the Ford side. Changing one is a PITA!
Glad we don't have to deal with this kinda thing on the Ford side. Changing one is a PITA!
Posting Guru
Joined: Dec 2004
Posts: 1,102
Likes: 3
From: Virginia - SW (Riner)
Yeah breaking one = engine rebuild for sure. Seems like they are unpredictable - some folks go way out to 120K and the belt looks great or they go @ 80-90 and trash the engine. Earlier 00-01's seem to have be the worst ones but VW didn't really make it any better until just recently. We have an 03 that went 110K on it's original belt and it looked great but I've learned that's not a good indicator because: I did a timing belt "inspection" @ 80k on another VW and it looked great - problem was it failed 4k later. 
Strokin Okie
Joined: Apr 2004
Posts: 1,883
Likes: 21
From: Oklahoma
Yeah breaking one = engine rebuild for sure. Seems like they are unpredictable - some folks go way out to 120K and the belt looks great or they go @ 80-90 and trash the engine. Earlier 00-01's seem to have be the worst ones but VW didn't really make it any better until just recently. We have an 03 that went 110K on it's original belt and it looked great but I've learned that's not a good indicator because: I did a timing belt "inspection" @ 80k on another VW and it looked great - problem was it failed 4k later.
They are still great vehicles. What other car will cruise down the road @ 80 mph and still put out 42mpg? BTW I live in turnpike country so 80 isnt speeding too much...
Posting Guru
Joined: Dec 2004
Posts: 1,102
Likes: 3
From: Virginia - SW (Riner)
We love our 03 - gets 40+ mpg most of the time and has been relatively trouble free save a few small things. Big thing for VW's - STICK to the maintenance schedule! - if VW says to do it - do it no later than what they say and preferably earlier. Brake fluid changes are another big one - neglect the 2yr change interval and you'll prob have a line rust from the inside out a year or 2 later.