NHTSA Complaint #10445783 — 2010 VOLKSWAGEN GOLF

INTER-COOLER DESIGN IS DEFECTIVE IN THAT IT ALLOWS CONDENSATION AND SLUDGE TO BUILD WITHIN THE CHARGE AIR INTAKE SYSTEM WHICH SUBSEQUENTLY FREEZES AND THAWS WITH LOW AMBIENT TEMPERATURE AND IT MOVES FURTHER AND FURTHER WITHIN THE INTAKE SYSTEM UNTIL THE CONDENSATE AND SLUDGE BECOME DRAWN INTO THE AIR INTAKE MANIFOLD AND BECOMES DISCHARGED INTO THE CYLINDERS CAUSING THE ENGINE TO HYDRO-LOCK AND FAIL. CAUSING POTENTIAL FOR PERMANENT AND CATASTROPHIC DAMAGE UPON RESTART. CURRENTLY FOR THIS MODEL, THE REPAIR IS COVERED UNDER THE MANUFACTURER'S WARRANTY ALONG WITH REPLACEMENT OF THE CHARGE AIR INTER-COOLER SYSTEM WITH A REDESIGN. IT REMAINS TO BE SEEN WHETHER THIS REDESIGNED SYSTEM INDEED SOLVES THE ROOT CAUSE OF THIS PROBLEM. HOWEVER, IF THE CAR IS BEYOND THE YEARS/MILES OF THE ORIGINAL MANUFACTURER'S OR EXTENDED WARRANTY, VW WILL NOT SUBSIDIZE THE REPAIRS TO THE ENGINE, NOR THE REPLACEMENT OF THE CHARGE AIR SYSTEM...EVEN THOUGH THE PROBLEM WAS DIRECTLY CAUSED BY THEIR DESIGN. THE OWNER WILL BE RESPONSIBLE FOR THE LARGE EXPENSE OF GETTING THE CAR RUNNING AGAIN. *TT