So, I have compiled a list of common issues and remedies for the 2.0T

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Thread: So, I have compiled a list of common issues and remedies for the 2.0T

  1. #1
    the deal finder!
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    So, I have compiled a list of common issues and remedies for the 2.0T

    So, I’ve compiled a list of common issues and common solutions based on what I’ve seen on the forums. Please research any possible fix before performing it. Personally, I’ve only had a bad pcv, so I’m basing a lot of this based on my understanding of the issue. Please let me know if something needs to be changed or added…I’d like to make this as good a possible.

    If your car is stock and you still have warranty, then all the items below should be covered under warranty. If you are not stock, then the failed component may or may not be covered under warranty depending on what caused the failure, though this thread is not a warranty debate thread.

    Disclaimer: This is a general guide only. Any problem with the car should be diagnosed by a competent and trained individual. All information provided is for information only and is not designed to replace a service manual or professional help. Use at your own risk.


    1. Diverter valve failure
    2. PCV failure
    3. Broken intake ducting
    4. Cam lobe wear
    5. High pressure fuel pump failure
    6. Air conditioning does not work
    7. Tumble flap failure
    8. Cold start problems
    9. Misfires
    10. Low fuel pressure sensor failure

    1. Diverter valve failure

    Background:
    The stock diverter valve (dv) is prone to failure, whether chipped or stock. The diaphragm is prone to tearing (the orange shown in the pic of the stock dv (in the middle) below-may be a different color depending on the version of dv you have.)

    Symptoms:
    -A failing diverter valve will generally lose boost.
    -The boost can be checked either via a boost gauge, or the vag-com (mb 115). You will see a huge drop in boost when the dv goes bad.
    -Pin-hole DV failures usually allow boost to spike, but will then suddenly vent boost.
    Tearing in the DV usually only allows 6-7 PSI. Boost will not spike.
    -You may see 000665 - Boost Pressure Regulation: Control Range Not Reached
    p0299 - 002 - Lower Limit Exceeded - Intermittent
    -Alternatively, you can remove the dv, and inspect the diaphragm for tears. It is held onto the compressor housing by three bolts:



    Solution:
    -You can replace it with the stock dv, vw #06F 145 710 C. This is the latest dv as of this post, however, many people have also seen failures with the “C” dv. VW is also supposedly coming out with a “G” dv, part # 06F-145-710-G, though it is not officially released as of this post.
    -You can upgrade to the Forge DV #fmfsitv. Pics of the Forge DV are shown above.

    2. Positive Crankcase Ventilation failure

    Background:
    The positive crankcase ventilation is supposed to let gases get sucked from the crankcase to the intake manifold when under vacuum. The problem is, when the pcv system fails, and allows positive pressure (boost) to go from the intake manifold back into the crankcase.


    The latest PCV is the “G” version. To see which version you have, take a small mirror, and stick it under the pcv valve. The last letter identifies the revision (“E” is shown below). The part # is under the round section:



    Symptoms:
    -Typically you will see a slight drop in boost pressure. When my pcv failed, I saw a 2 psi drop across the board.
    -Some oil will be pushed out through the oil filler cap, and onto the valve cover, and may possibly go towards the coil packs. There may also be some oil on the bottom side of the engine cover, where the oil filler cap is.
    -There might be a slight decrease in MPG.
    -Rear PCV failure usually results in oil accumulation around the DV, and will produce a little blue oil smoke at WOT applications.

    Solution:
    -There is the Digitalhippie fix which puts a check valve into the line from the crankcase to the intake manifold. For those who want a spare of the hose where the check valve is installed, the part number is 06F 103 221 F. You can read more about it here: http://www.golfmkv.com/forums/...=8952
    -You can also upgrade to the latest PCV “G” valve. There have been very few failures reported with this PCV. Please verify the PCV you have before upgrading.
    Part numbers for this upgrade:
    PCV valve cover assembly: 06F 129 101 G
    PCV valve cover gasket: 06F 103 483 E
    PCV valve cover to turbo hose: 06F 103 215 A
    PCV tube to turbo metal gasket: 06F 145 757 F

    -If you did the DH pcv fix, and you have a rear pcv failure, then you will need to change the tube labeled as "Exhaust turbocharged gas outlet" showin in the pic above. the Part #'s are the last two shown above (06F 103 215 A & 06F 145 757 F)

    3. Broken intake ducting


    Background:
    Some people have reported that part of the intake ducting that connects to the stock engine (the part in front of the accordion section) breaks off and gets lost, or worst, gets stuck and/or shredded by the fan. Due to its location, the loss in power should be minimal.



    Symptom:
    -You may notice that part of the ducting is missing.
    -You may see shreds of the ducting in and around the fan.
    -You may see the coolant temps rising possibly due to a part of the intake ducting getting stuck and not allowing the fan to turn. If the coolant gauge goes into the red, then immediately shut the engine off, and check to see if the fan is operating.

    Solution:
    -If the fan is damaged, then you may need a new fan.
    -An aftermarket intake will replace the ducting section, and is a possibly solution.
    -You might be able to tape or epoxy the sections together, so that it will make them harder to come apart. You may also remove the top piece alltogether.


    4. Cam lobe wear
    Background:
    Excessive wear of intake camshaft lobe that drives the high pressure fuel pump. The wear limits maximum pump piston lift, causing fuel rail pressure fluctuations. The intake cam drives the fuel pump:



    Please see also #5 below.

    Symptom:
    -Fuel cut-out when driving, esp. under WOT.
    -Fuel cut-out symptoms range from soft pulsations of power to long-pulse bucking while in high-gear high-load situations (high gear at WOT, or up a grade). MIL may flash if cut-out is severe. Car will also go into hard-limp (no boost, 4500RPM limit) if severe enough.
    -MIL ON
    -P0087 Fuel Rail / System Pressure - Too Low
    -P1093 Fuel Trim 2, Bank 1 Malfunction
    -P2293 Fuel Pressure Regulator 2 Performance

    Solution:
    Increase surface hardening of camshaft lobe for the high pressure fuel pump. Improved intake camshafts have Part No. 06F109101B. Refer to TSB# 15 07 04

    5. High pressure fuel pump failure

    Background:
    The high pressure fuel pump sometimes is not able to supply enough fuel, especially at low to mid range RPMs because it is cam driven. Please note that the high pressure fuel pump is different than the in-tank fuel pump. Please see also #4 above.



    Symptom:
    -Fuel cut-out when driving, esp. under WOT.
    -You may see the following DTC
    004767 - Low-Pressure Fuel Pressure Regulation: Pressure too High
    P129F - 001 - Upper Limit Exceeded - MIL ON

    Solution:
    -If you are chipped, then try to put the car in stock mode to see if the fuel cuts will stop. If it does, then you might want to wait until a fuel pump solution comes out. APR and Autotech are currently working on solutions.
    -If you are stock, then it is possible that you have a bad fuel pump. The dealer should replace this under warranty.

    6. Air conditioning does not work

    Background:
    The air conditioners manuf. By Zelex and Valeo tend to fail. They can be identified by the pulley:



    Symptom:
    - Air conditioning does not cool, air conditioning compressor may seize.

    Solution:
    - On the 2.0T engine a new Sanden compressor Part No: 1K0820803 index S must be installed. Refer to ETKA for the latest part # for the other engines. This should be covered under warranty.

    7. Tumble flap failure
    Background:
    The tumble flap motor is prone to failure. This is probably the most common problem I’ve seen when scanning cars with the vag-com. A little background on how the tumble flap works:



    Symptoms:

    You may see the following DTC’s
    -012599 - Intake Manifold Runner Control: Basic Setting not Completed
    P3137 - 001 - Upper Limit Exceeded – Intermittent
    -012691 - Intake Manifold Runner Control: Open Stop outside of Valid Range
    P3193 - 002 - Lower Limit Exceeded - Intermittent
    -008196 - Intake Manifold Flap; Bank 1: Stuck Open
    P2004 - 008 - Implausible Signal - Intermittent
    - 012600 - Intake Manifold Runner Control: Regulation Deviation
    P3138 - 008 - Implausible Signal - MIL ON

    Solution: The intake manifold flap motor needs to be replaced.

    8. Cold Start Problems

    Background/Symptom: Troubles starting car when cold

    Solution:
    -Some people have reported that it was related to a certain gas, so maybe try a different gas station/company.
    -Get the latest software reflash.
    -Could also be a bad coil pack.

    9. Misfires

    Background/Symptom:
    -Misfiring either under idle or under boost.
    -Scan for DTC’s. See which cylinder is misfiring, and swap coils and or plugs to see if the misfire follows.
    -Coil pack misfire (non-fire, lol) symptoms are shorter duration, rather violent, and also result in backfires from unburnt fuel entering the exhaust system. The MIL usually starts flashing. Car may or may not go into limp.

    Solution:
    -Replace coils and/or plugs
    -Could be a bad fuel injector


    A special thanks to DirtyDisco. and syntrix for providing some of the info used in this post.

    10. Low Fuel Pressure Sensor Failure


    Background/Symptom:
    You may get the following DTC’s:
    012555 - Low Pressure Fuel regulation: Fuel Pressure Outside Specification
    P310B - 008 - Implausible Signal - Intermittent - MIL ON

    004767 - Low-Pressure Fuel Pressure Regulation: Pressure too High
    P129F - 001 - Upper Limit Exceeded – Intermittent

    -The first symptom is typically stalling when first starting the car cold.
    -Typically, the problem gets worse, and can lead to fuel cutouts at almost any rpm and/or car stalling/running lean/rich

    Solution: Replace low fuel pressure sensor (thurst sensor), vw part #06E906051J
    Sometimes, the high pressure fuel pump will be replaced at the same time (#1 in pic below)

    Last edited by D.Passat00; 01-28-2008 at 10:32 PM.
    RichardSEL likes this.

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  3. #2
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    Nice list. This should be made a sticky.

  4. #3
    My intake has Emphysema R36Dreams's Avatar
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    Another reason for a B6 "Garage".

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  6. #4
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    that is really nice, now wheres the 3.6



  7. #5
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    It causes me some concern that there are already this many problems with this engine.

  8. #6
    My intake has Emphysema R36Dreams's Avatar
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    I haven't had these problems, but.....3K miles and I already had a strut bushing (think that's what they called it) collapse on me.

  9. #7
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    Good stuff here for future reference! I agree that it should be a sticky, at the least.

    Quote Originally Posted by D.Passat00 View Post
    6. Air conditioning does not work

    Background:
    The air conditioners manuf. By Zelex and Valeo tend to fail. They can be identified by the pulley:



    Symptom:
    - Air conditioning does not cool, air conditioning compressor may seize.

    Solution:
    - On the 2.0T engine a new Sanden compressor Part No: 1K0820803 index S must be installed. Refer to ETKA for the latest part # for the other engines. This should be covered under warranty.
    I don't know how detailed this compilation should be, but on this particular solution I think it's really, really important to note that when an a/c compressor seizes the whole system must be thoroughly flushed. Otherwise, there's a high liklihood that small metal fragments from the old compressor will get sucked into the new compressor and it will be ruined in short order. This would hopefully not be an issue on warranty repairs, but for someone who's car is beyond the warranty period and is either paying for the repair or DIY, it's critical.

    Thanks for you work on this list.

  10. #8
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    Quote Originally Posted by Marshalus View Post
    It causes me some concern that there are already this many problems with this engine.
    No joke! These all seem somewhat major -- I was hoping the 2.0t could be in my next car, but maybe not...

    A friend of a friend who bought a very early B6 had a lot of the issues you pointed out in this thread (esp. the starting issues) and I figured he just had a dud.

    How widespread are these problems? Any idea?

    Thanks for the great post.

  11. #9
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    Well so far 21000 km and no problems like these, except there is a little oil consumption, about 1/2 liter per 4000 km.

  12. #10
    the deal finder!
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    made some minor changes.

  13. #11
    4th Gear bass_lover1's Avatar
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    From browsing the MKV GTI forums, it seems that most of these problems occured on the 06s and very very early 07s, and that most of them have been worked out because of updated parts. Though the AC thing still seems to be hit or miss on the MY.

  14. #12
    the deal finder!
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    ^ updated

  15. #13
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    5200 miles on my '07 and not a single problem.

  16. #14
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    good info mane

  17. #15
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    Quote Originally Posted by D.Passat00 View Post
    So, I’ve compiled a list of common issues and common solutions based on what I’ve seen on the forums. Please research any possible fix before performing it. Personally, I’ve only had a bad pcv, so I’m basing a lot of this based on my understanding of the issue. Please let me know if something needs to be changed or added…I’d like to make this as good a possible.

    If your car is stock and you still have warranty, then all the items below should be covered under warranty. If you are not stock, then the failed component may or may not be covered under warranty depending on what caused the failure, though this thread is not a warranty debate thread.

    Disclaimer: This is a general guide only. Any problem with the car should be diagnosed by a competent and trained individual. All information provided is for information only and is not designed to replace a service manual or professional help. Use at your own risk.


    1. Diverter valve failure
    2. PCV failure
    3. Broken intake ducting
    4. Cam lobe wear
    5. High pressure fuel pump failure
    6. Air conditioning does not work
    7. Tumble flap failure
    8. Cold start problems
    9. Misfires
    10. Low fuel pressure sensor failure

    1. Diverter valve failure

    Background:
    The stock diverter valve (dv) is prone to failure, whether chipped or stock. The diaphragm is prone to tearing (the orange shown in the pic of the stock dv (in the middle) below-may be a different color depending on the version of dv you have.)

    Symptoms:
    -A failing diverter valve will generally lose boost.
    -The boost can be checked either via a boost gauge, or the vag-com (mb 115). You will see a huge drop in boost when the dv goes bad.
    -Pin-hole DV failures usually allow boost to spike, but will then suddenly vent boost.
    Tearing in the DV usually only allows 6-7 PSI. Boost will not spike.
    -You may see 000665 - Boost Pressure Regulation: Control Range Not Reached
    p0299 - 002 - Lower Limit Exceeded - Intermittent
    -Alternatively, you can remove the dv, and inspect the diaphragm for tears. It is held onto the compressor housing by three bolts:



    Solution:
    -You can replace it with the stock dv, vw #06F 145 710 C. This is the latest dv as of this post, however, many people have also seen failures with the “C” dv. VW is also supposedly coming out with a “G” dv, part # 06F-145-710-G, though it is not officially released as of this post.
    -You can upgrade to the Forge DV #fmfsitv. Pics of the Forge DV are shown above.

    2. Positive Crankcase Ventilation failure

    Background:
    The positive crankcase ventilation is supposed to let gases get sucked from the crankcase to the intake manifold when under vacuum. The problem is, when the pcv system fails, and allows positive pressure (boost) to go from the intake manifold back into the crankcase.


    The latest PCV is the “G” version. To see which version you have, take a small mirror, and stick it under the pcv valve. The last letter identifies the revision (“E” is shown below). The part # is under the round section:



    Symptoms:
    -Typically you will see a slight drop in boost pressure. When my pcv failed, I saw a 2 psi drop across the board.
    -Some oil will be pushed out through the oil filler cap, and onto the valve cover, and may possibly go towards the coil packs. There may also be some oil on the bottom side of the engine cover, where the oil filler cap is.
    -There might be a slight decrease in MPG.
    -Rear PCV failure usually results in oil accumulation around the DV, and will produce a little blue oil smoke at WOT applications.

    Solution:
    -There is the Digitalhippie fix which puts a check valve into the line from the crankcase to the intake manifold. For those who want a spare of the hose where the check valve is installed, the part number is 06F 103 221 F. You can read more about it here: http://www.golfmkv.com/forums/...=8952
    -You can also upgrade to the latest PCV “G” valve. There have been very few failures reported with this PCV. Please verify the PCV you have before upgrading.
    Part numbers for this upgrade:
    PCV valve cover assembly: 06F 129 101 G
    PCV valve cover gasket: 06F 103 483 E
    PCV valve cover to turbo hose: 06F 103 215 A
    PCV tube to turbo metal gasket: 06F 145 757 F

    -If you did the DH pcv fix, and you have a rear pcv failure, then you will need to change the tube labeled as "Exhaust turbocharged gas outlet" showin in the pic above. the Part #'s are the last two shown above (06F 103 215 A & 06F 145 757 F)

    3. Broken intake ducting


    Background:
    Some people have reported that part of the intake ducting that connects to the stock engine (the part in front of the accordion section) breaks off and gets lost, or worst, gets stuck and/or shredded by the fan. Due to its location, the loss in power should be minimal.



    Symptom:
    -You may notice that part of the ducting is missing.
    -You may see shreds of the ducting in and around the fan.
    -You may see the coolant temps rising possibly due to a part of the intake ducting getting stuck and not allowing the fan to turn. If the coolant gauge goes into the red, then immediately shut the engine off, and check to see if the fan is operating.

    Solution:
    -If the fan is damaged, then you may need a new fan.
    -An aftermarket intake will replace the ducting section, and is a possibly solution.
    -You might be able to tape or epoxy the sections together, so that it will make them harder to come apart. You may also remove the top piece alltogether.


    4. Cam lobe wear
    Background:
    Excessive wear of intake camshaft lobe that drives the high pressure fuel pump. The wear limits maximum pump piston lift, causing fuel rail pressure fluctuations. The intake cam drives the fuel pump:



    Please see also #5 below.

    Symptom:
    -Fuel cut-out when driving, esp. under WOT.
    -Fuel cut-out symptoms range from soft pulsations of power to long-pulse bucking while in high-gear high-load situations (high gear at WOT, or up a grade). MIL may flash if cut-out is severe. Car will also go into hard-limp (no boost, 4500RPM limit) if severe enough.
    -MIL ON
    -P0087 Fuel Rail / System Pressure - Too Low
    -P1093 Fuel Trim 2, Bank 1 Malfunction
    -P2293 Fuel Pressure Regulator 2 Performance

    Solution:
    Increase surface hardening of camshaft lobe for the high pressure fuel pump. Improved intake camshafts have Part No. 06F109101B. Refer to TSB# 15 07 04

    5. High pressure fuel pump failure

    Background:
    The high pressure fuel pump sometimes is not able to supply enough fuel, especially at low to mid range RPMs because it is cam driven. Please note that the high pressure fuel pump is different than the in-tank fuel pump. Please see also #4 above.



    Symptom:
    -Fuel cut-out when driving, esp. under WOT.
    -You may see the following DTC
    004767 - Low-Pressure Fuel Pressure Regulation: Pressure too High
    P129F - 001 - Upper Limit Exceeded - MIL ON

    Solution:
    -If you are chipped, then try to put the car in stock mode to see if the fuel cuts will stop. If it does, then you might want to wait until a fuel pump solution comes out. APR and Autotech are currently working on solutions.
    -If you are stock, then it is possible that you have a bad fuel pump. The dealer should replace this under warranty.

    6. Air conditioning does not work

    Background:
    The air conditioners manuf. By Zelex and Valeo tend to fail. They can be identified by the pulley:



    Symptom:
    - Air conditioning does not cool, air conditioning compressor may seize.

    Solution:
    - On the 2.0T engine a new Sanden compressor Part No: 1K0820803 index S must be installed. Refer to ETKA for the latest part # for the other engines. This should be covered under warranty.

    7. Tumble flap failure
    Background:
    The tumble flap motor is prone to failure. This is probably the most common problem I’ve seen when scanning cars with the vag-com. A little background on how the tumble flap works:



    Symptoms:

    You may see the following DTC’s
    -012599 - Intake Manifold Runner Control: Basic Setting not Completed
    P3137 - 001 - Upper Limit Exceeded – Intermittent
    -012691 - Intake Manifold Runner Control: Open Stop outside of Valid Range
    P3193 - 002 - Lower Limit Exceeded - Intermittent
    -008196 - Intake Manifold Flap; Bank 1: Stuck Open
    P2004 - 008 - Implausible Signal - Intermittent
    - 012600 - Intake Manifold Runner Control: Regulation Deviation
    P3138 - 008 - Implausible Signal - MIL ON

    Solution: The intake manifold flap motor needs to be replaced.

    8. Cold Start Problems

    Background/Symptom: Troubles starting car when cold

    Solution:
    -Some people have reported that it was related to a certain gas, so maybe try a different gas station/company.
    -Get the latest software reflash.
    -Could also be a bad coil pack.

    9. Misfires

    Background/Symptom:
    -Misfiring either under idle or under boost.
    -Scan for DTC’s. See which cylinder is misfiring, and swap coils and or plugs to see if the misfire follows.
    -Coil pack misfire (non-fire, lol) symptoms are shorter duration, rather violent, and also result in backfires from unburnt fuel entering the exhaust system. The MIL usually starts flashing. Car may or may not go into limp.

    Solution:
    -Replace coils and/or plugs
    -Could be a bad fuel injector


    A special thanks to DirtyDisco. and syntrix for providing some of the info used in this post.

    10. Low Fuel Pressure Sensor Failure


    Background/Symptom:
    You may get the following DTC’s:
    012555 - Low Pressure Fuel regulation: Fuel Pressure Outside Specification
    P310B - 008 - Implausible Signal - Intermittent - MIL ON

    004767 - Low-Pressure Fuel Pressure Regulation: Pressure too High
    P129F - 001 - Upper Limit Exceeded – Intermittent

    -The first symptom is typically stalling when first starting the car cold.
    -Typically, the problem gets worse, and can lead to fuel cutouts at almost any rpm and/or car stalling/running lean/rich

    Solution: Replace low fuel pressure sensor (thurst sensor), vw part #06E906051J
    Sometimes, the high pressure fuel pump will be replaced at the same time (#1 in pic below)




    Sent from my Autoguide iPhone app

  18. #16
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    Thanks, this stuff is still valid - years later.

    I notice that when I am under heavy acceleration the engine feels like it misses, pops (or??) I lose power and the engine light starts to blink. Could this also be the diverter valve crapping out?

    I'm replacing my coils this week. 90k miles on my 07 2.0t. I'm getting a cylinder1 misfire code. I also am also replacing the valve cover gasket as my spark plug recesses are full of oil.

  19. #17
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    loud winning noise and no exceleration

    would any of these issues cause a loud wineing and lose of power?

  20. #18
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    Thanks for taking the time for this Post.

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