31 Other Known Failures/Technical Service Bulletins
Description
This article is from the Watercooled VWs General FAQ, by Jan Vandenbrande with numerous contributions by others.
31 Other Known Failures/Technical Service Bulletins
This section contains common known failures reported by VW users or
VW magazines, and "official" Technical Service Bulletins (TSB) from VW.
The TSBs are VWs way to tell all the mechanics: "If you see this
problem, do that". That's all. They are NOT recalls, and do not
imply any financial comittments.
If your car is under warrantee you will not have to pay, if not, you pay.
With any problem, you always have to be able to recreate it.
However, not all dealers are up to date with their TSBs (:-<) and
on some occasions we can use knowledge of these TSBs to point to
a potential solution and also point out that your case may not be
unique. The TSBs are identified by a number: V35-92-01. See elsewhere
in this FAQ on how to obtain them (I have to rearrange things a bit
as soon as I have time).
83-86 GTI, GLIs, 84-86 Cabriolets, 83-86 Sciroccos except 16V, 84-86 Cabs:
Self Machining Transmission due to lack of snap rings on the differential
shafts. See April 1990, EuroCar pp 53, "VW 020 Gearbox Failures: Causes and
Cures". Only Close ratio transaxles are affected.
Starting at serial number 15102 (built after october 14th 1982).
Serial numbers up to 14102, (built up to October 14,1982) are immune.
VW part#171-498-088 offers the clips as part of the rebuild kit.
(Another sources says: If either rivet has been removed, secure the
differential pinion shaft with circlips, Part No. N 042 363 1.)
Gear oil leaking under the tranny, or strange noises are first signs,
between 50k and 120k miles.
NO RECALL! Sue VW. Techtonics Tuning is recommended by VW&P to fix self-
machined cases (probably because they wrote the article).
See also the archive: Tranny_Clip_Failures
78-8? R/J I:
Fuel pump relay recall. Fries itself. FI cars only.
Fix = move relay for better cooling.
87-89 Jetta & 84 GTI & 83-84 Scirocco?:
Front brake line recall.
85-? Golf & Jetta, GTI/GLI:
Heater Core failure. Recall.
85-86 GTI & GLI:
Engine hop problems. Requires a hop kit and/or upgraded front engine
mount.
89-90? Jetta:
RT Recall - Leaking steering rack recall?
85-91 Golf II & Jetta II, GTI/GLI:
Rough cold idle & stalling problems. Several causes see the technical FAQ
for possible diagnosis.
85-?86 GTI/GLI:
Recall RC, Code PC 13: Transfer pump failure.
85-?86 Golf:
?Recall PC?: Clean/replace transfer pump fuel screen.
Symptoms: Transfer fuel pump becomes noisy.
85-?86 GTI/GLI/Jettas/Golfs:
v13-89-01: connecting rod repair.
85OCT-85DEC and 84OCT-85SEP GTI:
NV/NW Recall (86V149000 & 86V029000) - Fuel tank replacement due to non
compliance with FMVSS 301.
87-89? Scirocco:
Gas tank leaks. Recall. (weren't other cars affected?)
16V Engines:
Drive belt failure around 50k miles. Breaks valves!
Remedy: Replace belt at 50k miles!
89-92 16V 9A CA:
SB Recall - Ca. smogged 9A engines, hanging idle switch.
Not officially announced by VW as yet. Non-CA have a less severe problem.
Fix: New throttle body assembly.
90-on Corrado
V13-91-06 - Abnormal engine noise with warm engine at 1800 to 2500 rpm
The connecting rod may float on the crankshaft causing a metallic
noise between stated rpm range.
In severe cases, instal crankshaft Part No: 026 105 101E
90-91 Corrado G60/Passat:
V35-90-01 - Transmission binding in reverse. Replace/lube back up light
switch, check shift rod cover (Part 02A 919 835), MoS2 grease on shifter &
shift linkage
90-9x? Corrado/Passat/Golf/GTI/Jetta/Cabriolet/Vanagon:
V30-93-04: Shifting difficulties - 020, 02A & 025 Manual Transmission
Clutch disk binding on spline ==> dragging.
Replace clutch with Cadmium coated spline.
90-91 G60:
V35-92-01 - Mods on 02A gears and shafts.
???-??-?? - Replace muffler hangers to reduce droning/vibration
V13-91-06 - Metallic knocking noise between 1800 and 2500 rpm caused
by out of tolerance connecting rod or crankshaft.
If severe, replace crankshaft.
90-? Passat/Golf/Jetta/Fox/Corrado:
V42-93-01: Rear Tire Wear
This Service Bulletin supersedes: V42-92-01 & V42-90-02.
Fix: Replace rear stub axles.
Note: This problem has been most prevalent on Passats with Continentals.
Updated axles are= 357 501 117B (for Passats)
91-94 Corrados, Passat GLX
94 Golf & Jetta III
95 Cabrio
V28-94-01 (Aug 1, 94): Sparkplugs listed in the owner's manual and other
service literature may not be correct.
90-? Passat:
Rear window regulators. Service bulletin exists. See recall SW.
90-? Passat:
Mysterious gauge fluctuations on Passats and Foxes...
There is a VW service bulletin for the Passat showing a procedure to fix this
problem.
The voltage regulator is not usually bad, but they frequently is not well
soldered. The bulletin explains how to re-solder thge gerulator to the
circuit board. Since I mentioned that I knew of this bulletin,
my friendly dealer called VW and got the repair authorized under warranty...
90 Passat/Auto:
Car won't start: Replace transmission switch.
90-92 Corrado
87-88 Scirocco
88-92 Jetta
88 GTI
90-92 GTI & Passat
V28-91-01: No Start/Hard Start/Poor running
Problem: High tension arcing on distributor caps resulting in poor
starting and poor running.
90-91 Corrado (PG Engine)
V28-92-07: Cannot attain High Speed (supersedes V28-91-02)
Fix: Check knock sensor & replace if needed
90 Corrado
V24-91-01: Engine does not start at first attempt
Fix: Cut wire to digifant unit terminal 23 in ECU plug.
91 Corrado SLC/VR6, Passat
V34-92-04: 5 Speed Transmission 02A Gearshift Mechanism Modified
All transmissions as of 03 09 1 have the new mechanism (which includes
the counter weight). Old cars except for the G60 can be upgraded.
93-94: Jetta /// GL
Moonroof rattle. There is a TSB out on this.
CA DIESEL FUEL:
The environmentally friendly diesel fuel being sold in CA since Oct 93
is rumored to destroy the injector pump seals.
Call: Califronia Trucking Association, Mike Thomas, (916) 373-3534
who is collecting claims.
California Air Resources Board 1-800-952-5588 leave your name address,
etc and a complaint about what happened to your vehicle.
Gov. Wilson's office (916) 445-2841
In California, I've just read
that Univ of Dayton (Ohio) scientist has finally figured out what went
wrong with the Low-Aromatics-Diesel introduced in California. Apparently
the lack of armomatics and sulfur allowed oxidation of the fuel (when
meeting up with heat and oxygen) to form peroxide. This peroxide wasn't
detected in the fuel, but was found on the damaged oil rings. All major
refiners in Calif. are now blending anti-oxidant additives.
(per U.S. Oil Week 6/06/94)
Today's newspaper (9/3/94) reported that legislation to repay those of
us who have lost diesel injector pumps from the 'new and improved' diesel
fuel, has been signed by Gov Re_Pete Wilson.
Reimbursment of up to $450 bucks for cars and $550 bucks for trucks
will be alloted to those who have suffered damages.
Details on how to get reimbusrsed will be published in the newspapers later
this year. The Senate and Assembly passed the bill in August.
March 1, 1995 is the deadline for filing a claim with the State of
California for replacement or reimbursement for damages to your
diesel pumps. Trucks are entitled up to $1,000, cars are $450.
Call 1-800-272-2667 to get a form sent to you.
TSB ACCESS
==========
The Technical Service Bulletins are now to be had ONLINE for a small
fee from ALLDATA:
/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\
For FREE trial access to the World's Largest Database of
Vehicle Repair and Maintenance Information, including detailed
information about any of the above bulletins, visit ALLDATA at:
WWW : http://www.alldata.tsb.com
GOPHER: gopher.alldata.tsb.com
or e-mail Theresa@alldata.com for more information.
\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/
NOTE that some car parts supermarkets allow you to retrieve and
print out this data for free as well.
Here is a sample of the free index available through WWW:
JETTA /// TSB
-------------
[jeremyh@ftp.amcc.com]
Year: 1994
Make: Volkswagen
Model: Jetta III
Engine: 4-1984cc 2.0L SOHC
JAN 94 1. OBD BASIC ENGINE SETTING AFTER DISCONNECTING BATTERY JAN 94 2. POOR DRIVEABILITY DEC 93 3. FRONT AND REAR VW EMBLEMS-REPLACING DEC 93 4. WINTER TIRES/SNOW CHAINS DEC 93 5. VACUUM DOOR LOCKS NOV 93 6. AUTOMATIC TRANSMISSION 096, VALVE BODY REPLACEMENT NOV 93 7. HORN PAD REMOVAL NOV 93 8. INDUSTRIAL FALLOUT, REPAIRING PAINT FINISH NOV 93 9. GOLD PLATED TERMINAL REPLACEMENT NOV 93 10. CLEANER FOR INTERIOR SURFACES NOV 93 11. ENGINE COOLANT TEMPERATURE SENSOR (ECT) REPLACEMENT NOV 93 12. IDLE SPEED HUNTS WHEN COLD NOV 93 13. REAR TIRE WEAR NOV 93 14. TROUBLE CODES 00533 & 2231 (ISC NOISE DAMPER CLOGGED) NOV 93 15. WATER LEAK AT ENGINE BULKHEAD SEALING PROCEDURE NOV 93 16. GUIDELINES FOR WARRANTY REPAIRS NOV 93 17. AUTOMATIC TRANSMISSION REPAIR OCT 93 18. LOANER CAR CHARGES FOR PAINT/CORROSION WARRANTY REPAIRS OCT 93 19. M.Y. 1994 WARRANTY COVERAGE INFORMATION OCT 93 20. NEW 16-PIN DATA LINK CONNECTOR - ACCESSING/CONNECTING SEP 93 21. RADIO SECURITY CODE STICKER, NEW LOCATION SEP 93 22. 1,000-MILE CONSULTATION PROCEDURES FOR 1994 MODELS SEP 93 23. 1994 PDI PROCEDURE AND MAINTENANCE/LUBRICATION SCHEDULES
>>>>MORE???? Pls provide recall campaign & number & a 1 line description
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