Another sucker stuck with dead 2006 Jetta TDI

[bgbearnavy]

Car finally paid off, then bam! I have 175,000 miles was hoping for more, but the crap hit the fan. My camshaft has eaten two lobes, my dual mass flywheel is dead, and also my Exhaust Gas Cooler is leaking. It has been very disappointing. I am not surprized that there isn't a recall on the cams and DMF!!!!!

[chittychittybangbang]

Recalls are usually over safety issues, not mechanical defects. IMHO they should fix it but they're not. Live and learn.

If it makes you feel any better, fixing the current car is almost always cheaper than buying a new one. If you have a 5 spd, replace flywheel with SMF, replace cam and EGR cooler, and you have a car that will last a long time since the problems are now fixed.

[bgbearnavy]

I have the 6 speed

[chittychittybangbang]

The DSG is 6 speed, the manual is 5 speed. So if you have a DSG you can only get another DMF since SMF won't fit DSG.

[Dmcampbell]

Same just happened to our 2006 Jetta DSG TDI at 92,000 miles - so you should feel lucky to have gone that far!! So, never having worked on the TDI before, but being very mechanically involved in older Porsches, I tackled it all myself with the use of a friend's lift, trans jack and an above engine bar support over two weekends. I sourced the D'M'F' flywheel (newest version), Colt Stage 2 cam kit w/ lifters, bearings and hardware, the EGR cooler with the three gaskets (2 for cooler/ 1 for upper turbo oil drain) needed, the heater core coolant hoses, Q-Loader Tune and a Osirius skid plate all from Kerma TDI. Paul and staff were fantastic help and he gave me great pricing on the package. I also purchased a Timing belt kit (TB, Water Pump, Tensioner, idler pulley, Accessory belt, coolant and tools) from DieselGeek, but in hind sight I should have just sourced these from Kerma as well. I then proceeded in the following general order: Drain oil and coolant; Remove trans, R&R flywheel, install trans; removed timing belt; R&R cam, bearings & lifters; R&R water pump, tensioner, idler; Time and install Timing and accessory belts; R&R EGR Cooler & heater hoses; Refill coolant/oil w/ new filter and drove for a week. Then I installed the Kerma tune w/ the Q-Loader and the power is amazing! Car runs better than new - quick starts and smooth idle with little smoke under full throttle. I am now seeing about 37mpg around town and 51+mpg on hwy at 75 mph! I Have about 600 miles on car after all the work and plan to change oil/filter again at 1000 miles. B/T/W, torquing of all fasteners is essential and although I did source new subframe stretch bolts from Diesel Geek, which must be removed to drop DSG, the dealer advises they never change these. Obviously, you must use new flywheel bolts. In all I think I spent about $3,000 in parts, but saved nearly that much or more in labor. Good luck, Mike