Gas Recirculation Valve (egr Valve) problems of the 2010 Volkswagen Jetta Sportwagen

Faulty egr system puts moisture in the turbo intercooler on the diesel 2. 0 engine. Intercooler eventually freezes in cold temperatures. Engine dies randomly due to no turbo boost. My car died while making a left hand turn across 2 lanes of oncoming traffic. We were almost t-boned by a semi truck hauling a 53� trailer! my dealer had one other tdi in the shop the same day mine was towed in. Vw has engineered a � cold weather intercooler� and is aware of this design flaw. Nothing is mentioned in the owner's manual about draining the water (which isn't supposed to be there) from the system occasionally during warm weather. Cars under the 36,000 mile warranty have had the updated intercooler installed for free. This update, that didn't fix the problem, cost me $1042. 92. The car stalled during the drive home from the dealership immediately after the new cold weather intercooler was installed. It stalled 2 out of 3 subsequent trips after the updated intercooler. The car had to be towed due to the engine starting and immediately stalling. This issue arose after the vw tdi emmissions fix that was performed on my car in December of 2017.

Successfully starting and driving the car for 3 days of below freezing temps at 40mph average. Put car in 40deg garage overnight. Started car in the morning in garage, it ran for about 3-5 seconds then stopped. Restart acted like dead battery; half turn of crank, then nothing. Suspecting a dead battery, I put a charger on and tried again half an hour later; still no start, just half turn then nothing. Tried again about every half hour for 3 hours until it finally started, then it seemed to be running on 3 cyl for about 15-20 sec until it started to run smooth. Took to dealer where they tested battery and charging system; everything within specs and no codes. They kept car outside overnight at 20 degrees and it started right up the next morning. I investigated this issue on several tdi forums and it seems this is attributed to ice forming in the intercooler then thawing when warmed up. Engine will start normally until it ingests the water/vapor that shuts it down. Several owners are reporting half cup to two cups of water drained out of intercooler hoses. Several owners are reporting engine either shutting down or going into limp mode on highway after ice blocks intake sufficiently. Most are suspecting the lp egr circuit that is pumping moist air back into the intake/intercooler causing condensation to accumulate then freeze. I notified dealer when they had the car and they did not investigate water in intercooler as requested. I suspect this is hydrolocking the engine and that serious engine damage will occur if this continues during the cold months. Several forum members in canada are reporting that vw of USA knows about this and is working on a solution but nobody has seen anything yet. Several dealers are recommending the removal of the fresh air intake pipe to draw warm, underhood air into the intake; this does not seem to affect the icing as the moisture seems to be coming from the exhaust stream via the lp egr.

Hi, we purchased a 2010 vw jetta tdi sportwagen in September of last year and within the first 300 miles it went into a limp mode with reduced power and the glowplug light was flashing. I limped home at half power and parked it. When I went to start it to see what the mileage was the car had no problem. I made the dealer aware of this and they blew it off as a fluke and if it happened again to call them. At around 750 miles we were driving on the highway and were passing a car when the car again went into a reduced power limp mode and almost caused me to get into an accident since the person behind me almost rear ended us. I had to very carefully pull over to the side of the road at 10:00 pm. I shut the car off and restarted it after waiting 2 minutes and it started up again like nothing happened. I called my dealer and made an appointment to drop it off telling them I don't want it back until the problem is fixed. They kept it for two weeks and drove it around putting 500 miles on it that they said were trouble and event free. They couldn't replicate the problem and when they ran a diagnostic they found that the egr valve was throwing a code. They said that they checked it, cleared the code and that's it. Now after almost 10,000 miles we never had a problem again but I do believe they did a secret fix and gave it back to me. It was very scary to have the stalling happen to me out of the blue on the highway. Someone needs to investigate this.