NHTSA Complaint #10667791 — 2006 VOLKSWAGEN JETTA

WAS GETTING HEAD ACHES WHEN DRIVING THE CAR AND SITTING IN TRAFFIC OR AT A STOP LIGHT. SMELLED A SULFUR LIKE SMELL FROM THE ENGINE COMPARTMENT. COULD HEAR LOUD BLOWING SOUNDS ON ACCELERATION. DEALERSHIP FOUND AN EXHAUST LEAK IN THE BACK OF THE DIESEL MOTOR FROM THE EGR COOLER ASSEMBLY. THE ENGINE WAS BLOWING SOOT IN TO THE ENGINE COMPARTMENT AND IT COULD BE HEARD AND SMELLED THROUGH THE FIREWALL. THIS IS A DIESEL SO THE EXHAUST CONTAINS CARCINOGENIC CHEMICALS. DIESEL EXHAUST CONTAINS A NUMBER OF POTENTIALLY TOXICOLOGICALLY RELEVANT ORGANIC COMPOUNDS ACCORDING TO THE EPA THAT HAVE HUMAN HEALTH HAZARDS ASSOCIATED WITH EXPOSURE. THE EGR COOLER IS NOT COVERED UNDER THE 8 YEAR 80K FEDERAL EXHAUST EMISSION WARRANTY EVEN THOUGH IT IS A MANDATED PART OF THE EXHAUST SYSTEM AS PART OF THE EXHAUST GAS RECIRCULATION SYSTEM. A SHAFT GOING THROUGH THE WALL OF THE EGR COOLER CONNECTING TO A BUTTERFLY VALVE USED TO DIVERT THE EXHAUST GASES IN TO THE COOLER HAS A FAULTY SEAL THAT WILL FAIL AND ALLOW THE EXHAUST GAS TO EXIT THE EXHAUST IN TO THE ENGINE COMPARTMENT AND GET IN TO THE PASSENGER COMPARTMENT. THIS IS NOT ONLY AN EPA VIOLATION BUT A HEALTH HAZARD TO EVERY VW TDI OWNER OR PASSENGER. TO REPAIR THE ACCORDING TO THE DEALERSHIP, THE EGR COOLER HAS TO BE REPLACED AT A COST TO THE OWNER OF $1000. VW CUSTOMER CARE WILL NOT STAND BEHIND THE PRODUCT BUT DID REALIZE THE ISSUE AND OFFER REPLACEMENT IN THE FIRST 2 YEARS OR 24K MILES. MOST ISSUES OCCUR AT 70K TO 120K MILES BECAUSE OF A POORLY DESIGNED PART. *TR