VW TDI engines in the “PD” family are prone to camshaft wear and failure. Learn more about the problems and how you can minimize them.

If you own a 2004-2006 Golf, Jetta, New Beetle, Jetta Wagon or Passat TDI you vehicle is equipped with a “Pumpe Duse” – or PD – series engine. These engines are unique in that each fuel injector has its own pump and makes its own pressure. Read more about the PD Engines here…

Camshaft Failure Issues

PD camshaft experience much higher stresses because the camshaft is operating both the valves, like a normal cam would, AND the individual unit pumps on the injectors. This stress has caused accelerated wear on the lobes of the camshaft and the lifters that control the valves.

PD Camshaft Failure Symptoms

Engines experiencing camshaft failure will exhibit the same set of symptoms. The main symptom is increased noise from the cylinder head. This noise is immediately identifiable by anyone who has experience with this engine. Additionally engine performance may be reduced with lower power, fuel economy and more exhaust smoke. Ignoring these symptoms can lead to a severe or catastrophic failure of the lifter and valves, risking drastic engine damage.

PD Camshaft Failure Causes

While the increase stresses of the unique design contributed to failure, the materials chosen for these components are equally to blame as they were insufficient for the design. The factory design used standard manufacturing casting and hardening for the camshaft along with standard material for the lifters. Both these components were insufficient in hardness in order maintain durability in use. New revised parts include solid billet construction camshafts and lifters with black nitrided plating for increased hardness.

Other things may contribute to camshaft failure, like improper engine oil (VW TDI Engine Oil Specifications) or failure of the combination fuel and vacuum pump – also referred to as the tandem pump – on the side of the cyclone head. (Read about Tandem Pump Failure & Camshaft Failure on PD TDIs).

PD Camshaft Repair

Repairing a worn or failed camshaft requires removing the valve cover, injector rockers and camshaft to replace a set of components including:

• Camshaft
• Camshaft Bearings
• Lifters
• Camshaft Cap Bolts
• Injector Rocker Bolts
• Tandem Pump Gasket

When choosing a replacement camshaft it is recommended to choose a solid billet construction camshaft, if available, rather than a cast camshaft. A solid billet camshaft will have increased hardness and durability. Because of the increase in hardness billet camshafts must be paired with black nitrided lifters.

Because the camshaft is driven by the timing belt it is a good idea to consider replacing the timing belt when replacing the camshaft as doing both jobs together is more time efficient. (Shop PD Timing Belt Kits)