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Volkswagen Jetta 2.0 TDI 140hp Highline common faults.

2005–2011, saloon, diesel, 140 HP.

The fault list covers: BKD, BMM, CBDB engine, MQ350 transmission.

What you save stays on this device only. My saves

7 fault write-ups. 5 important. 5 recalls.

If you know the year, pick it. Faults for other years drop out of the list.

Before you buy

Known faults

5 important faults

critical1

The PD (pump injector) unit is held in the cylinder head by a single side bolt. Over time the seat works itself loose: the mounting slackens, the copper ring no longer seals, and hot combustion gas blows past. First you hear a characteristic "puffing", rhythmic blowing noise from the top of the engine when cold, soot appears under the cam cover, and then the seat surface in the cylinder head erodes. At that point replacing the seal is not enough: the head has to be refurbished or replaced. It affects PD engines between 1998 and 2010, regardless of size.

What to check

  • After a cold start open the bonnet and listen above the cam cover for a rhythmic blowing, "puffing" noise
  • Shine a light around the cam cover and the injectors: oily soot indicates blow-by
  • Ask whether a PD unit or a copper ring was replaced, and whether a compression test was done afterwards
1 more steps in the write-up

expensive4

The EGR valve and its cooler block up with soot and oily deposits; the particulate filter cannot regenerate on short urban trips. The signs are reduced power, a warning light, and frequent regeneration. The software update after the diesel emissions affair made the EGR operate more often, which accelerated the phenomenon: the maker gave goodwill repairs in several cases.

between 140,000 and 160,000 km

What to check

  • Ask what kind of journeys the car did: a daily short urban run is the worst for the filter
  • With a code reader look at the stored faults (P0401/P0402, and P2002 for the filter)
  • Ask whether it received the post emissions affair software update, and when
1 more steps in the write-up

The internal springs of the flywheel tire, and the two discs knock against each other. The signs are a rattling or knocking from the bellhousing at idle and when releasing the clutch pedal, and vibration through the floor. If the clutch slips without a burnt smell, that also points to the flywheel. It is worth replacing in time: a disintegrated flywheel can destroy the bellhousing too. At a clutch replacement the two go together anyway.

What to check

  • At idle, without touching the clutch pedal, listen for the rattle from the bellhousing, then press the pedal: if it stops, that is suspect
  • Watch for the characteristic clatter on starting and switching off
  • Put your foot on the floor at idle: a noticeable vibration indicates tired springs
2 more steps in the write-up

The PD injectors (on the 1.4, 1.9 and 2.0 TDI alike) are driven by the camshaft itself, against more than 2,000 bar. That wears the lobes and the rockers quickly: first a knocking noise, then a rough idle, hard starting and loss of power. The cause is the wrong oil: the PD engine requires a 5W-40 lubricant to the VW 505.01 specification, with PD approval. A plain synthetic is not enough, and on an everyday 5W-30 the lobes can wear through.

What to check

  • Listen for knocking from the cam cover when cold: that is the first sign
  • Ask for the service book and check what oil was used (VW 505.01)
  • Watch how even the idle is, and whether it starts hard when cold
2 more steps in the write-up

The vanes of the variable geometry turbo are glued together by soot and oil arriving through the EGR. First you get overboost or a lack of boost, then loss of power above 2,000 rpm, and finally limp mode. Caught in time it is enough to remove the turbo, clean it and fit a new actuator rod. Short urban trips and gentle, low rev driving speed up the deposits.

What to check

  • On the motorway, load it above 2,000 rpm: does it pull evenly, or does the power break up
  • Watch whether the warning light flashes up under acceleration (overboost protection)
  • Ask what kind of journeys it did: a daily short urban run is the worst
1 more steps in the write-up

comfort1

The G62 sensor tells the engine control unit how hot the coolant is. If it is faulty, the control unit thinks a warm engine is cold, and runs it rich: hard warm or cold starting, a rough idle, markedly increased fuel consumption, and a dash temperature gauge that jumps around or never reaches its usual reading. The part is cheap and can be replaced in half an hour: the trouble is that many people do not recognise it and replace an injector or a lambda sensor instead. If the fault persists, the rich mixture can destroy the catalytic converter too.

What to check

  • Warm it up and watch the dash temperature gauge: the needle should sit steadily at the middle reading, not jump around
  • Watch a cold start, then a warm start after twenty minutes standing
  • With a code reader look for the 17664 / P1256 code in the engine control unit
2 more steps in the write-up

cheap repair1

The G28 sensor drops out as it heats up. While driving the car stops, then starts again after a few minutes. When warm it starts with difficulty or not at all, while cold it starts, so the workshop often cannot reproduce it. The fault code does not always stay stored either.

What to check

  • Ask specifically: has it ever stopped while driving, and did it start again afterwards
  • Run it up to temperature, switch it off for 10 minutes, then restart: long cranking is suspect
  • With a code reader look for the stored (not just the active) engine control faults
1 more steps in the write-up

Checklist

Volkswagen Jetta 2.0 TDI 140hp Highline

First what you would check on any car. Then the faults of this model.

Before you buy

Checklist

The printed sheet starts with what you would check on any car. What you tick stays on this device only.

On every car

Ask the owner

vinkodex.com · Before you buy it, see what can go wrong.

Official recall5 recallsShow

The manufacturer fixes these for free at a franchised dealer. Ask with the VIN whether it was done.

Most recent: 10 December 2010

10V621000FUEL SYSTEM, GASOLINE:DELIVERY:HOSES, LINES/PIPING, AND FITTINGSFUEL SYSTEM, GASOLINE:DELIVERY:HOSES, LINES/PIPING, AND FITTINGS10 December 2010 · NHTSA (USA)

VOLKSWAGEN IS RECALLING CERTAIN MODEL YEAR 2006-2010 JETTA, NEW BEETLE, NEW BEETLE CONVERTIBLE, MODEL YEAR 2009 JETTA SPORTWAGEN AND MODEL YEAR 2007-2009 RABBIT VEHICLES EQUIPPED WITH 2.5L ENGINES. THE JETTA, JETTA SPORTWAGEN, AND RABBIT VEHICLES MAY HAVE A SMALL PLASTIC TAB LOCATED ON THE WINDSHIELD WASHER FLUID RESERVOIR THAT MAY CHAFE AGAINST AN UNDERHOOD FUEL SUPPLY LINE. THE NEW BEETLE AND THE NEW BEETLE CONVERTIBLE VEHICLES MAY HAVE A FASTENING CLAMP ON A HYDRAULIC HOSE OF THE POWER STEERING SYSTEM THAT MAY BE LOCATED IN AN IMPROPER POSITION WHICH COULD CAUSE CHAFING AGAINST AN UNDERHOOD FUEL SUPPLY LINE.

Risk: IF CHAFING OCCURS, THERE IS THE POTENTIAL FOR A FUEL LEAK TO DEVELOP. FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.

Remedy: DEALERS WILL INSPECT AND IF NECESSARY REPLACE THE UNDERHOOD FUEL LINE. ADDITIONALLY, DEPENDING ON THE VEHICLE MODEL, DEALERS WILL EITHER REMOVE THE PLASTIC TAB FROM THE WINDSHIELD WASHER FLUID RESERVOIR, OR INSPECT THE POSITION OF THE FASTENING CLAMP AND ADJUST THE RELATED FASTENING CLAMP INTO THE CORRECT POSITION. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE SAFETY RECALL IS EXPECTED TO BEGIN ON OR BEFORE JANUARY 31, 2011. OWNERS MAY CONTACT VOLKSWAGEN AT 1-800-822-8987.

The authority's notice

09V164000POWER TRAIN:DRIVELINE:DRIVESHAFTPOWER TRAIN:DRIVELINE:DRIVESHAFT19 May 2009 · NHTSA (USA)

VOLKSWAGEN IS RECALLING 25,594 MY 2006-2009 JETTA 5TH GENERATION EQUIPPED WITH 2.01 ENGINE. THE FASTENING SCREW CONTACT SURFACES ON THE DRIVESHAFT COVER PLATE MAY NOT HAVE BEEN MANUFACTURED TO FACTORY SPECIFICATIONS. SOME SCREWS MAY NOT HAVE BEEN TORQUED PROPERLY DURING ASSEMBLY AND COULD LOOSEN OVER TIME, CAUSING A KNOCKING SOUND WHEN THE VEHICLE IS IN MOTION. THE DRIVESHAFT SCREWS COULD LOOSEN TO THE POINT WHERE THE DRIVESHAFT DETACHES FROM THE GEARBOX.

Risk: IF THE VEHICLE IS MOVING WHEN THIS HAPPENS, THE DETACHED DRIVESHAFT COULD CAUSE DAMAGE THE GEARBOX HOUSING. A DAMAGE GEARBOX HOUSING COULD LEAK GEARBOX OIL ONTO THE STREET AND CREATE A RISK OF A VEHICLE CRASH FOR BOTH THE DRIVER AND OTHER MOTORISTS.

Remedy: DEALERS WILL INSPECT THE DRIVESHAFT SCREWS AND REPLACE THE SCREWS FREE OF CHARGE. THE RECALL BEGAN ON JUNE 24, 2009. OWNERS MAY CONTACT VOLKSWAGEN AT 1-800-822-8987.

The authority's notice

07V442000EXTERIOR LIGHTING:HEADLIGHTSEXTERIOR LIGHTING:HEADLIGHTS24 September 2007 · NHTSA (USA)

CERTAIN VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." SOME VEHICLES MAY NOT HAVE HAD A REQUIRED CAP INSTALLED WHICH DISABLES THE HEADLIGHT HORIZONTAL AIM AND SOME VEHICLES MAY CONTAIN A CAP THAT DISABLES THE VERTICAL AIMING SCREW.

Risk: NONCOMPLIANCE CAN INHIBIT PROPER HEADLAMP AIM ADJUSTMENT FOR ROADWAY ILLUMINATION, IMPROPERLY AIMED HEADLAMPS COULD CAUSE REDUCED ROAD VISIBILITY, INCREASING THE RISK OF A CRASH.

Remedy: DEALERS WILL INSPECT FOR THE PRESENCE OF A CAP IN THE SOCKET OF THE LOW BEAM HORIZONTAL AIMING SCREW AND INSTALL ONE IF MISSING, AND INSPECT FOR THE PRESENCE OF A CAP IN THE SOCKET OF THE VERTICAL AIMING SCREW AND IF PRESENT, THE CAP WILL BE REMOVED. THE RECALL WILL BEGIN ON OCTOBER 31, 2007. OWNERS MAY CONTACT VW AT 1-800-822-8987.

The authority's notice

07V284000VISIBILITY:WINDSHIELD WIPER/WASHERVISIBILITY:WINDSHIELD WIPER/WASHER25 June 2007 · NHTSA (USA)

CERTAIN VEHICLES EQUIPPED WITH 2.5L GASOLINE ENGINES MAY HAVE A SMALL PLASTIC TAB LOCATED ON THE WINDSHIELD WASHER FLUID RESERVOIR THAT MAY CHAFE AGAINST THE UNDERHOOD FUEL SUPPLY LINE.

Risk: IF THIS HAPPENS, THE CHAFING HAS THE POTENTIAL TO CAUSE A FUEL LEAK OVER TIME. FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE COULD RESULT IN A FIRE.

Remedy: DEALERS WILL REMOVE THE PLASTIC TAB FROM THE WINDSHIELD WASHER FLUID RESERVOIR AND WILL ALSO INSPECT AND, IF NECESSARY, REPLACE THE UNDERHOOD FUEL SUPPLY LINE. THE RECALL BEGAN ON AUGUST 24, 2007. OWNERS MAY CONTACT VW AT 1-800-893-5298.

The authority's notice

A12/00222/20Safety recallInjuriesno date · EU Safety Gate

Cars initially used for internal purposes of Volkswagen AG might not have been correctly modified before they were sold to the general public. There is a possibility that certain safety systems of these cars are not correctly modified for street use.

Remedy: Type of economic operator taking notified measure(s): Manufacturer Category of measure(s): Recall of the product from end users Date of entry into force: Unknown

The authority's notice

Engine and transmission

3 engines · 1 transmissions

BKD · 2.0 TDI

103 kW (140 HP) · diesel

MQ350 · 6-speed manual

manual · 6 speed

Torque limit400 Nm
MakerVolkswagen

We built the code from the model and the gear count. The factory sheet does not state it. More than one engine code is possible. The fault list shows the faults of each.

Variant data

What is in this version

Factory data

Trim
Highline
Body
saloon
Fuel
diesel
Transmission
manual
Engine size
1968 cc
Power
103 kW (140 HP)
Drive
FWD
Production
2005–2011

Factory service interval

The manufacturer specifies this for this version. Of the mileage and the time, the one that comes first is the one that counts.

  • Air filter

    • 60,000 km or 4 years
  • Cabin (pollen) filter

    • 30,000 km or 2 years
  • Engine oil and oil filter

    • LongLife30,000 km or 2 years(valid only with LongLife-approved oil)
    • 15,000 km or 1 year
  • Brake fluid change

    • first: 3 years, then 2 years(first change at 3 years, then every two years)
  • Timing belt, 1.6 / 2.0 TDI (EA188/EA189/EA288)

    • 210,000 km(EA288, including the 1.6 TDI, with no time limit. 130,000 miles = 209,215 km. Parts maker repair specification, read by a human. The interval chart at https://www.rwcmotorsport.com/tech/tdi-maintenance.php gives the same figure independently.)
  • Coolant (antifreeze) change

    • first: 193,000 km or 10 years, then 97,000 km or 5 years(G13 / G12++: first change at 120,000 miles or 10 years, then every 60,000 miles or 5 years)
  • Fuel filter, diesel

    • 60,000 km or 2 years

Information, not an expert opinion

We write the descriptions, and we put the source next to them. A person reviews them before they go out. They are still information, not a technical expert opinion.

  • A fault on the list does not mean the car you are looking at has it.
  • A fault missing from the list does not mean the model is fault-free. Write-ups are made model by model. Not all of them are done.
  • You decide whether to buy. This is no substitute for an inspection. That needs a workshop and a history check.
Details in the terms