KNOWN FAULTS · Volkswagen

Volkswagen Transporter T5 1.9 TDI PD common problems.

2003–2015 · Diesel

Sources are not verified in real time and no entry confirms that your car is affected.

3 known faults with sources

PD TDI camshaft, injectors and cylinder headInjection / cylinder head

Engine / equipment: 1.2, 1.4, 1.9 and 2.0 TDI unit-injector (PD) engines, including the VW-sourced 2.0 CRD in Chrysler, Dodge and Jeep
Period mentioned: 2000–2010
Symptoms: Growing noise from the cylinder head, power loss and rough running (cams and lifters); unstable idle, smoke or hesitation (injectors); on the 16-valve 2.0 TDI, coolant loss with no visible leak from a cracked head.
Possible cause described: The camshaft also drives the unit injectors and carries a heavy load: without VW 505.01 oil the lobes and lifters wear. 2.0 TDI PD injectors fail frequently. Some 16-valve 2.0 TDI heads (part number ending in A) crack; VW considered it fixed by the end of 2006.
Check for the garage: Check the oil history (VW 505.01), listen to the head, check injector balance rates with a diagnostic tool and, on the 16-valve 2.0 TDI, read the head part number (03G 103 351) and look for coolant loss.
Cost cited in the source: Camshaft and lifters: approx. €400–800; 2.0 TDI PD injectors: €900–2,000A rough figure from the original database, not an up-to-date quote.

Mileage cited in the database: 120,000–200,000 km. This is not a maintenance interval and does not predict a failure.

Applies if: Only if fitted with the air conditioning system described.

A/C not cooling: N280 valveClimate control

Engine / equipment: Air conditioning with clutchless compressor and N280 regulating valve (combustion VW, Audi, Seat, Cupra and Skoda from 2006)
Period mentioned: 2006–2026
Symptoms: The air does not cool or cools intermittently (for example only at motorway speed), and sometimes the compressor rattles with the A/C on. Codes 01232 (N280 valve), P2612 or 00898.
Possible cause described: The compressor regulates its output with the N280 solenoid valve, its most common failure point. Audi issued technical bulletins over a manufacturing fault in this valve on Sanden compressors. Its connector can also become brittle and corrode (especially without the engine undertray), or the wiring fails.
Check for the garage: Read the codes and N280 control current with VCDS or ODIS, measure its resistance (about 10 ohms) and check the connector and wiring before replacing parts. If the valve or compressor is replaced, the whole circuit must be flushed.
Cost cited in the source: N280 valve: a cheap part (about 30 dollars) where sold separately; new compressor with circuit flush: considerably moreA rough figure from the original database, not an up-to-date quote.

Applies if: Only all-wheel-drive versions (4Motion, transverse-engine quattro, 4x4 or 4Drive) with a 4th or 5th generation Haldex coupling.

Haldex all-wheel-drive coupling pumpTransmission

Engine / equipment: 4th and 5th generation Haldex coupling in transverse-engine VAG all-wheel-drive cars: VW 4Motion, A3/TT/Q3 quattro, Skoda 4x4 and Seat/Cupra 4Drive
Period mentioned: 2007–2020
Symptoms: All-wheel-drive warning or a pump error in diagnostics, the car behaves like front-wheel drive (wheelspin in the wet or on gravel) and sometimes no cluster warning even with stored codes.
Possible cause described: The electric pump that pressurises the coupling loses flow because the filter (4th generation) and the pump strainer clog with wear debris; dirty oil raises its current draw and burns it out. According to forum owners, dealer services often change the oil but not the filter or strainer, and a new pump fails again if this is skipped.
Check for the garage: Read the all-wheel-drive module with VCDS, OBDeleven or ODIS (ODIS shows the pump current) and check in the history when the oil was changed and whether the filter was replaced and the strainer cleaned. After servicing, an adaptation with diagnostic equipment is recommended on generations 4 and 5.
Cost cited in the source: Oil, filter and strainer cleaning: maintenance. If the clutch plates are destroyed, an S3 owner quotes about £4,000 to replace the whole unit.A rough figure from the original database, not an up-to-date quote.