Jetta - Volkswagen :: 2004 - Won't Start Smoothly - Would Crank But Not Fires Up


Apr 25, 2013

I have a 2004 Jetta TDI Stationwagon. In January it started having starting problems. The car would crank but not fire. After about 8-9 tries it would fire. MOstly does it first crank of the day (whether morning or afternoon).

Mechanic #1 said it was the fuel filter and changed it. But it still had starting problems. Then Mechanic #1 said it was a sensor and changed it. Still had starting problems. In February, Mechanic #2 said it was the fuel pump. Changed the fuel pump. Still had starting problems.

Then Mechanic #2 said it was the crank sensor. But when he checked the crank sensor was brand new (apparently Mech #1 changed it in January). Still had same starting problems.

Mechanic #3 said he received the Crank sensor diagnostic error too but he checked it and it was brand new! He told me to take it to the dealer. I did. Dealer said no it wasn't the crank sensor it was the new fuel pump installed in April was defective. Took off the brand new fuel pump that was installed another brand new fuel pump. Next day car started fine but two days later didn't start again. Took car back to the dealer. They said after all it wasn't the fuel pump it was the crank sensor. After a couple days they said it wasn't the crank sensor but it was the EGR valve that was clogged with carbon. They changed the EGR valve, cleaned it out and gave the car back to me.

Today the car doesn't start again! I tried it about 7 times! Dealer is going to haul it back and try to figure it out! But I am frustrated! What could it be?

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We have a 2004 Jetta with about 92,000 miles on it. We bought it used in October 2012 after 3 months needed rebuilt transmission, and many other problems but the most recent has been costly with no mechanic being able to repair. These are some of the problems that we are faced with. While in drive the vehicle feels like its gonna stall but starts to beep the clock resets and car continues to drive with no problems or the car won't start at all.

You open the car door no keys are in the ignition but the car is clicking and clock and miles are fading in and out, light on door panel blinking, you push flashers and it makes a strange noise but flashers are not blinking. You put key in and try to start the car and nothing the blinking and clicking stop and it does nothing turn key back in off position clicking and blinking start again.

Car just stalls when approaching stop signs. No mechanic has been able to fix problem or duplicate issues. I do have video of the interior clicking and flashing and noises it makes.

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I checked the voltage of my battery after sitting for 6 hours and it was 12.3 (through the diagnostic screen). The battery is only about a 1.5 years old.

A couple times I go to start the car and the dashboard lights turn on and off, the brake pedal feels like the hydraulic turns on and then off (with the lights) and it just cycles like this, unless you turn it off. Sometimes it starts after a few cycles.

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1) Leave the vehicle parked overnight - no issues starting. It starts right up.

2) Crank the vehicle after having only been off a few minutes (like after you run in to pick something up at the grocery store) it cranks right up.

3) Let the vehicle sit for between 1 and 4 or 5 hours and the problem appears. It turns over and over and over but won't actually start. Anywhere between the 3rd and 5th turn of the key it will finally catch and actually crank.

In all cases, once it cranks it runs smoothly and normally with no issues.

I have replaced the battery thinking that was the issue but that did not fix the problem. Also strange is the fact that this problem occurred after I replaced both front door speakers, an operation that required me to have one or more doors open for an hour or so at a time (hence why I thought it might be a weak battery).

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2. During first few miles of driving, I hear a tick-tick-tick-thump sound coming from the rear of the car that is not related to tires/engine/speed/etc. The thump sound is pretty loud. The tick-tick-tick sounds like some type of piston-actuated pump. After >10 miles or so of driving, these sounds stop.
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All of this started two weeks ago with no previous issues.

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When the car is completely cold, the engine typically turns over a few times before starting up. Sometimes a few turns into seven or eight, but I've never had it not start. The problem comes when I've driven it somewhere (like to the grocery store, yoga class, or to get gas, to name a few) and try to restart it after my task is done. The warmer the engine, the lower the chance it will start. In it's most extreme, the car will not start at all, and I have had it stall out on me at stoplights if I do manage to get it started.

The car has had a history of intermittent hard starts in the four years I've had it, but nothing at all like this.

In the past two weeks, my mechanic has replaced the coolant temperature sensor, thermostat and seal ring, serpentine belt tensioner and serpentine belt, power supply relay, fuel pressure regulator and seal rings and the crank sensor. They've also been able to see that something is off about the fuel pump since they can see air bubbles in the fuel line, but thought I could push the car for a while without having to replace the pump.

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