Recalls: Volkswagen 2K Caddy
Overview
Manufacturers, or importers, issue recalls for defects or faults which have the potential to cause injury. Generally, manufacturers will inform the original buyers if their vehicle is subject to a recall and of the steps required to remedy the defect or fault. Please note that the recalls below (if any) are for Australian-delivered vehicles only. Furthermore, the number of recalls should not be taken as an indication of a model’s reliability or its safety more generally.
Recalls: Volkswagen 2K Caddy
2006 Volkswagen 2K Caddy: rear axle clamps could break
In July 2007, a recall was issued for 2007 model year Volkswagen Caddy vehicles that were manufactured between July 2006 and August 2006. In these vehicles, the spring clamps on the rear axle could break because of poor heat treatment (PRA 2007/9426).
2008-09 Volkswagen 2K Caddy with 6sp DQ250 DSG: loss of power
In June 2013, a recall was issued for Volkswagen 2K Caddy vehicles that had six-speed DQ250 Direct Shift Gearboxes (DSGs); AustralianCar.Reviews understands that the recalled vehicles were manufactured from 1 September 2008 to 31 August 2009. In these vehicles, the wiring harness of a temperature sensor within the transmission may have insufficiently crimped connector wires. This could cause the temperature sensor to incorrectly detect high gearbox oil temperatures and activate the clutch protection function – this would illuminate a flashing gear warning light and cause 1) juddering of the vehicle, 2) a reduction in engine torque, and 3) opening of the clutch (as if the gearbox were in ‘neutral’). As such, loss of power to the wheels could pose a hazard to occupants of the vehicle and other road users. For the recalled vehicles, Volkswagen provided a software update for the gearbox control unit (PRA 2013/13625).
2008-11 Volkswagen 2K Caddy with 7sp DQ200 DSG: loss of power
In June 2013, a recall was issued for Volkswagen 2K Caddy vehicles that were fitted with seven-speed DQ200 Direct Shift Gearboxes (DSGs) and manufactured between June 2008 and September 2011. In these vehicles, sulphur in the gear oil and an inorganic heat stabiliser in the plastic parts (iodine) of the mechatronic unit could cause metallic surfaces to suffer from electrolytic corrosion, particularly in conditions with high temperatures and humidity. Conducting particles could then settle between the circuit paths of the control unit and cause a short circuit and blow the gearbox fuse. If the fuse were to blow, the clutch would open and freewheel, resulting in a sudden and total loss of power to the wheels. Although other vehicle systems such as steering and braking would continue to function, the loss of power may pose a hazard to vehicle occupants and other road users (PRA 2013/13626).
2013 model year Volkswagen 2K Caddy with 7sp DQ200 DSG: loss of power
In November 2013, a recall was issued for 2013 model year Volkswagen 2K Caddy vehicles with seven-speed DQ200 DSG transmissions. In these vehicles, electrolysis of sulphur constituents in the synthetic oil could cause them to separate and accumulate between electrical conductor paths. In turn, this could create a short circuit and blow the gearbox fuse, causing the clutch to fully open. While the majority of failures occurred on start-up when the vehicle was stationary, a failure when the vehicle was in motion would result in a sudden loss of power at the wheels. All other functions of the vehicle, however, would remain active. As part of the recall, the synthetic transmission oil was to be replaced with mineral oil (PRA 2013/13835).
Pre-2013 Volkswagen 2K Caddy: boot lid could drop unexpectedly
In March 2014, a recall was issued for Volkswagen Caddy vehicles that were manufactured prior to January 2013. In these vehicles, the attachments of the ball pin for the gas pressure spring on the D-pillar may loosen. If this occurred, the ball pin could subsequently tear off and cause the boot lid to drop down unexpectedly – this could pose an injury risk (PRA 2014/14006).
2010-15 Volkswagen 2K Caddy 1.6 TDI and 2.0 TDI: NOx emissions
In October 2015, a recall was issued for 2010-15 Volkswagen 2K Caddy vehicles with 1.6- and 2.0-litre EA189 diesel engines. According to the recall notice, ‘the emissions levels may not meet regulatory requirements when the affected vehicle is driven under normal conditions’ (see ‘Diesel engines: NOx emissions “defeat device”‘, below). For the 1.6-litre EA189 engine, a ‘flow transformer’ will be fitted directly in front of the air mass sensor and a software update will be introduced. The flow transformer is a mesh screen that reduces the swirl of the air flow upstream of the air mass sensor so that the sensor can more accurately measure intake air volume. For the 2.0-litre EA189 engine, a software update will be introduced which takes advantage of improved simulation of air currents inside the air intake system. Volkswagen aims to implement the software update from January 2016; the labour time for installing the updated software is around half an hour. Owners could determine if their vehicles were part of the recall by visiting volkswagendieselinfo.com.au (PRA 2015/14950).
2012-13 Volkswagen 2K Caddy: engine could start when unlocking vehicle
In December 2015, a recall was issued for 2012 and 2013 Volkswagen Caddy vehicles. In the recalled vehicles, the earth attachment of the on-board power supply control unit may not have been correctly tightened. In certain circumstances, the starter motor may crank the engine when unlocking the vehicle; if the vehicle was left in gear, the vehicle could then move and pose a hazard (PRA 2015/15133).
2009 and 2010 model year Volkswagen Caddy: ABS and ESC may not operate
In March 2017, a recall was issued for 2009 and 2010 model year Volkswagen Caddy vehicles. In these vehicles, thermal overload within the ABS/ESC control unit could interrupt the current flow and this could prevent the ABS and ESC systems from functioning as intended; a warning light would also illuminate on the dashboard. In critical driving situations, the absence of ABS and ESC could increase the risk of a collision and injury to vehicle occupants. As part of the recall, the software for the ABS/ESC control unit would be updated to regularly check the operation of the unit (PRA 2017/15956).
2011-15 model year Volkswagen 2K Caddy Van DSG: pressure accumulator crack and loss of power
In October 2019, recall campaign 35D8 was issued for 2011-15 model year Volkswagen 2K Caddy Van vehicles. Due to a production fault, a crack in the transmission’s pressure accumulator (within the mechatronics housing) could occur. If the pressure accumulator cracked, oil and pressure would be lost in the hydraulic system of the gearbox. If this occurred, the transmission of engine power would be interrupted, similar to depressing the clutch in a vehicle with a manual transmission – this increased the risk of a collision and injury to vehicle occupants. For the VINs of the recalled vehicles, please see PRA 2019/17886. AustralianCar.Reviews understands that the recalled vehicles had seven-speed DQ200 DSG transmissions.
2011-15 Volkswagen 2K Caddy with 7sp DSG: loss of drive
In April 2020, recall campaign 34J5 was issued for Volkswagen 2K Caddy vehicles that had seven-speed dual clutch (‘DSG’) transmissions. In these vehicles, a fluid leak could lead to a loss of pressure in the gearbox. This pressure loss could interrupt the transmission of power between the engine and gearbox, causing a loss of drive – this increased the risk of a collision and posed a hazard to both vehicle occupants and other road users. For the VINs of the recalled vehicles, please see PRA 2020/18258.
Problems and faults: Volkswagen 2K Caddy
Overview
This section identifies potential problems, causes and fixes based on the experiences of owners and repairers, online sources and technical service bulletins. This information is provided solely for reference purposes and AustralianCar.Reviews recommends that only properly qualified persons carry out repairs or modifications. Furthermore, the number of items below should not be taken as an indicator of a model’s reliability or the frequency with which they may occur.
To report a problem or fault to the AustralianCar.Reviews team, please use the Contact Us form. Note that AustralianCar.Reviews does not offer advice on automotive problems or disputes; such enquiries will not receive a reply. For vehicles purchased from dealers after 1 January 2011, please see our Australian Consumer Law fact sheet.
2010-11 VW Caddy 1.2 TSI: stretched timing chains (CBZ engines)
Models and engines affected
For Volkswagen Caddy 1.2 TSI vehicles with CBZA, CBZB and CBZC engines that were manufactured prior to 18 June 2011, the timing chain was susceptible to elongation (or stretching). In Australia, these models were marketed as the Caddy TSI160 and Caddy 175. Symptoms of a stretched timing chain include:
- A rattling noise from the engine bay; and,
- If the timing chain skips teeth on its sprocket, the valve timing may be disturbed. This could cause rough running, illumination of the ‘check engine’ light and, at worst, contact between the valves and pistons which causes serious engine damage.
If the engine warning light illuminates, the vehicle should not be driven.
Repair kit
Since the original timing chain (part no. 03F 109 158B) was susceptible to elongation, Volkswagen released a repair kit (part no. 03F 198 229 A) which included:
- A reinforced chain (part no. 03F 109 158 K); and,
- A new chain guard with anti-jump teeth (initially, part no. 03F 109 210 C and, subsequently, part no. 03F 109 210 D).
Whilethe 03F 198 229A repair kit prevented the timing chain from stretching, there may still be a rattling noise heard in the first five seconds after start up from the hydraulic chain tensioner since it takes time to accumulate oil pressure. Since the spring inside the chain tensioner loosens over time, this rattling noise is more likely to be heard on older, higher mileage 1.2 TSI engines.
June 2011 production changes
This revised chain and chain guard were incorporated into production from 18 June 2011 – this corresponds to engines numbers after:
- CBZ* 462774 (for Mlada Boleslav production); and,
- CBZ* 714253 (for Salzgitter production).
The production location can be determined by inspecting the sticker on the boost pressure pipe or on the intercooler (‘M’ for Mlada Boleslav or ‘S’ for Salzgitter).
November 2011 production changes
On 7 November 2011, new versions of the CBZ engines were introduced (part no. 03F 103 101 B). For the post-November 2011 CBZ engines, changes included:
- A wider timing chain (part no. 03F 109 158 G);
- New chain guides (03F 109 509 and 03F 109 469 E);
- A black chain tensioner (changed material and size); and,
- An improved upper sprocket (changed materials and tooth design).
As such, the post-November 2011 1.2 TSI are not susceptible to the start-up rattle noise of the earlier engines. For reference purposes, however, the timing chain repair kit for these engines has the part no. 03F 198 158 B.
Pre-2012 VW Caddy 1.2 TSI (CBZ): shim and ECU update
For pre-2012 Volkswagen Caddy vehicles with the 1.2 TSI engine (engine codes CBZA, CBZB and CBZC), the Mahle Rotary Electronic Actuator (REA) may malfunction due to the variable nozzle turbine (VNT) sticking as a result of carbon build-up. This may cause the following symptoms:
- The Electronic Power Control (‘EPC’) warning light would illuminate and the vehicle would enter ‘limp home’ mode;
- When slowing down in second gear (for example, prior to cornering or entering a roundabout), the driver may experience delayed power delivery when trying to subsequently accelerate; and,
- Error code P334B (Charge Pressure Control Actuator – Mechanical Malfunction) may be logged when driving, particularly when lifting off after heavy acceleration.
For Australia, the potentially affected vehicles were the Caddy TSI160 (CBZA) and Caddy TSI175 (CBZB).
To fix,
- A 2 mm shim was to be fitted between the wastegate actuator and the turbo body; and,
- The engine control unit (ECU) was to be updated to calibrate the new actuator position.
It is understood that the ECU re-programming also provided more progressive power delivery.
Some owners experienced rough running subsequent to these measures being implemented. While dealers advised that this should resolve itself within 800 kilometres (500 miles), owners have reported that this has not always been the case.
Pre-2011 VW Caddy 1.2 TSI: #3 cylinder HT lead failure
For pre-2011 VW Caddy 1.2 TSI models, the high tension (HT) lead for cylinder three passes close to the exhaust manifold. Due to the heat of the exhaust manifold and the lack of insulating material for the HT lead, the lead can be damaged and cause the following symptoms:
- The Electronic Power Control (‘EPC’) warning light illuminates and the vehicle enters ‘limp home’ mode;
- Rough running; and/or,
- Loss of power.
It is understood that the HT leads on post-2012 1.2 TSI engines had heat-resistant sleeves at the coil end to protect against heat radiated from the exhaust manifold.
VW Caddy 1.6 TDI and 2.0 TDI diesel engines: NOx emissions “defeat device”
Australian-delivered Volkswagen 2K Caddy vehicles powered by 1.6- and 2.0-litre diesel engines that were available for sale from 2010 to 2015 had software in the electronic control module (ECM) that could sense – via sensors measuring the position of the steering wheel, vehicle speed, the duration of the engine’s operation and barometric pressure – when the vehicle was undergoing emissions testing. The ECM would then run a ‘dyno calibration’ to produce lower nitrous oxide emissions during testing. At all other times, the ECM would run a separate ‘road calibration’ which reduced the effectiveness of the emission control system, specifically the selective catalytic reduction (SCR) or the lean NOx trap.
Based on testing conducted by the EPA and the California Air Resources Board (CARB), NOx emissions for the ‘road calibration’ were 10 to 40 times higher than US standards – this led the United States Environmental Protection Agency (EPA) to issue a notice of violation under the Clean Air Act.As a result, these vehicles did not meet the environmental standards claimed by Volkswagen.
