Workshop Manuals Factory service & repair Volkswagen

Volkswagen common faults and how to fix them

Faults that are well known on Volkswagen models we hold manuals for: what the owner notices, what causes it, and the pages in our manuals that cover the repair.

VW PCV valve: 2.0T rough idle, misfire and lean codes (2006–2012)

Symptoms

The engine light comes on, the idle is rough or hunting, and there may be a whistle or other noise from the engine. Typical fault codes are P2187 and P1297 (system too lean at idle), P2279 (intake air leak) and misfire codes P0300 to P0304. It affects the 2.0T in the GTI, Jetta, GLI, Eos, CC, Passat and Tiguan.

Cause

The 2.0T engines vent crankcase gases through a breather (PCV) valve in the oil separator on top of the engine. Its diaphragm splits or the valve sticks, so unmetered air leaks into the intake and the engine runs lean. VW ran a required update (17D1) to replace the crankcase breather valve on the 2.0T FSI, and later issued a crankcase breather diagnosis bulletin for the 2.0 TSI.

Fix

Before chasing vacuum leaks with a smoke test, read the fuel trims: VW's 2.0T PCV valve diagnosis bulletin uses them to confirm a breather fault first. If the valve is faulty, the Mk6 GTI PCV valve and oil separator come off the top of the engine. The same part is behind most Tiguan PCV valve faults, as the engine is shared. On 2.0T FSI (BPY) engines, check whether VW PCV valve update 17D1 has been done. Clear the codes and recheck the fuel trims afterwards.

Repair instructions on this site

Sources: VW technical bulletin 10-11-01; VW required vehicle update 17D1 (bulletin 01-08-26).

VW ignition coil failure: 1.8T and VR6 misfire (2001–2003)

Symptoms

The engine misfires and shakes, loses power, and the engine light comes on or flashes, with misfire codes P0300 to P0306 stored. It often starts with one cylinder and can come and go with heat and damp. It affects the 1.8T and 2.8 VR6 in the Golf, GTI, Jetta, New Beetle and Passat, and the VR6 in the EuroVan.

Cause

These engines use a separate coil on each spark plug. The coils fitted to many 2001–2003 cars fail early, cracking internally so the spark tracks to earth. VW replaced them under a campaign in June 2004 (WG), covering 1.8-litre and 2.8-litre engines in the New Beetle, GTI and Jetta, 1.8-litre and 4.0-litre engines in the Passat, and 2.8-litre engines in the EuroVan.

Fix

Read the misfire codes and swap the suspect coil with one from another cylinder: if the misfire moves, the coil is faulty. Check the spark plug at the same time. A VW ignition coil replacement is quick on the 1.8T, as the coils sit on top under the engine cover. VW's later P0300 VW Jetta and GTI misfire bulletin for recall 28F3 sets out the checks. Fit coils of the current part number, not old stock.

Repair instructions on this site

Sources: VW campaign WG (June 2004); VW technical bulletin 28-10-02 (recall 28F3).

VW timing chain tensioner: 2.0 TSI failure in the GTI, Jetta, Tiguan and CC (2008–2012)

Symptoms

A rattle from the timing chain for a few seconds after a cold start. If the tensioner fails, the chain jumps teeth: the engine runs badly or will not start, with a camshaft and crankshaft correlation fault such as P0016. In the worst case the valves hit the pistons.

Cause

The first 2.0 TSI (EA888, engine codes CCTA and CBFA) uses a hydraulic chain tensioner that can lose its hold on the chain, especially after standing. A US class action filed in 2016 named the 2008–2012 Golf, GTI, Jetta and Passat, and the Audi A3 and TT, with these engines, alleging tensioners that fail early. The same engine is in the Tiguan, CC and Eos.

Fix

Treat a cold-start rattle as a warning. Check the tensioner position through the inspection opening in the timing cover before deciding on a repair. A timing chain VW Jetta repair replaces the tensioner with the revised part, along with the chain and guides if worn. The VW Tiguan timing chain layout is the same. If the chain has already jumped, check the valves before refitting the cover.

Repair instructions on this site

Sources: CarComplaints.com — Volkswagen timing chain tensioner lawsuit (2016); Kessler Topaz Meltzer & Check — Volkswagen timing chain cases.

VW DSG problems: gearbox shifts to neutral (2009–2010 recall)

Symptoms

While driving, the DSG gearbox suddenly drops into neutral and the car loses drive. The gear position display in the instrument panel flashes and the "depress brake pedal" light comes on. Other DSG problems on these cars, such as jerky shifts or warning lights, are usually traced to the mechatronic unit that controls the gearbox.

Cause

NHTSA recall 09V333000 covers about 16,000 2009 Eos and 2009–2010 GTI, Jetta and Jetta SportWagen with the DSG, built between September 2008 and August 2009. Wires in a temperature sensor connector were not crimped properly, so the sensor can falsely report a high gearbox oil temperature and the gearbox protects itself by selecting neutral.

Fix

Check with a VW dealer whether the VW DSG recall has been done: the remedy is an inspection and, if needed, a new temperature sensor, free of charge. For other faults, read the gearbox fault memory first. The sensor is part of the VW mechatronic unit, which can be removed with the gearbox in the car. After any work on it, the gearbox needs its basic settings run with a diagnostic tool.

Repair instructions on this site

Sources: NHTSA recall 09V333000; Wikipedia — Direct-shift gearbox.

VW window regulator: Mk4 Golf, Jetta and GTI windows that drop or stop working

Symptoms

A front door window drops into the door, goes up crooked, or the motor runs but the glass does not move. Often there is a crunching or clicking noise from inside the door first. It is common on the Mk4 Golf, GTI and Jetta, and the bulletin also appears in our Beetle manuals.

Cause

VW bulletin 64-08-05 gives the cause as broken or damaged cables or clamps in the front door window regulator. The plastic clamps that hold the glass to the regulator crack, and the cable can fray or come off its pulleys. VW introduced new cast clamps to replace the plastic ones.

Fix

Remove the door trim and the door's inner carrier assembly to reach the regulator. If only the clamps have broken, fit the new cast clamps on both sides of the glass, as the VW window regulator bulletin requires. Clean the glass, scuff the rubber isolators and bond them with adhesive as described. If the cable is damaged, replace the regulator. The Golf window regulator procedure covers removing the carrier, and the Jetta is the same.

Repair instructions on this site

Sources: VW technical bulletin 64-08-05 (supersedes 64-07-05).