2004 Volkswagen Golf diesel: common problems and MOT failures

What goes wrong more than usual on a 2004 Volkswagen Golf diesel?

Parts flagged at MOT more often on the 2004 Volkswagen Golf diesel than on all cars registered in 2004.

• Suspension arm bushes and joints2.2× usual
  Volkswagen Golf

  20.6% All 2004 cars

  9.3%

  Failed outright at MOT: 4.1%, against 2.1% of all 2004 cars. The rest were advisories or minor defects.

  Rough price £120–£180 (one arm) ClickMechanic

  At the viewing: Listen for clunks over bumps and feel for the steering wandering. Worn arm bushes show as cracked rubber near the wheels.

• Drive shaft (CV) joints2.6× usual
  Volkswagen Golf

  17.3% All 2004 cars

  6.6%

  Failed outright at MOT: 6.7%, against 3% of all 2004 cars. The rest were advisories or minor defects.

  Rough price £60–£350 our estimate

  At the viewing: Drive slowly on full steering lock in both directions and listen for clicking. Look for split rubber boots behind the front wheels.

• Sub-frame2.2× usual
  Volkswagen Golf

  11.1% All 2004 cars

  5.1%

  Failed outright at MOT: 0.3%, against 0.3% of all 2004 cars. The rest were advisories or minor defects.

  Rough price £300–£1,000 our estimate

  At the viewing: Look underneath at the frame the suspension bolts to. Flaky rust or holes are expensive to fix.

• Flexible brake hoses1.8× usual
  Volkswagen Golf

  9.8% All 2004 cars

  5.6%

  Failed outright at MOT: 3.4%, against 1.2% of all 2004 cars. The rest were advisories or minor defects.

  Rough price £50–£200 our estimate

  At the viewing: Look for cracked or bulging rubber hoses behind the wheels and in the engine bay.

• Rust in key structural areas3.5× usual
  Volkswagen Golf

  4.9% All 2004 cars

  1.4%

  Failed outright at MOT: 3.9%, against 1% of all 2004 cars. The rest were advisories or minor defects.

  Rough price £80–£250 our estimate

  At the viewing: Pull each seatbelt sharply. It should lock, and retract cleanly.

Common 2004 Volkswagen Golf diesel MOT failures and advisories

The share of 2004 Volkswagen Golf diesel MOT tests where testers flagged each area, as a fail or an advisory. Rough prices are typical independent-garage costs.

• Suspension
  56% of testsRough price £120–£400

  At the viewing: Listen for knocks over speed bumps, and look behind each front wheel for a snapped coil spring.

• Brakes
  43% of testsRough price £150–£350

  At the viewing: Look for a lip on the disc edges and feel for judder or pulling when braking firmly from about 40mph.

• Lights and electrics
  43% of testsRough price £10–£80

  At the viewing: Ask a friend to check every light, including brake lights and indicators, while you operate them.

• Tyres
  38% of testsRough price £70–£150

  At the viewing: Check the tread on all four tyres, including the inside edges, and look for cracks or bulges.

• Driveshafts and joints
  17% of testsRough price £60–£350

  At the viewing: On full steering lock, drive slowly and listen for clicking from the front wheels.

• Rust and bodywork
  14% of testsRough price £150–£1,000

  At the viewing: Check the sills, wheel arches and underneath for rust, and look along the panels for uneven gaps or paint.

Known faults on the 2004 Volkswagen Golf diesel

Reported by owners, mechanics and buying guides for this model and age. Check which engine the car has, as some apply to one engine only.

• Dual-mass flywheel

  Manual and DSG

  The dual-mass flywheel can fail, giving a scraping or rattling noise at a cold idle and extra vibration. It’s an expensive fix, usually done with a new clutch.

  At the viewing: Listen at a cold idle, then press the clutch and see if the noise fades.

  Source: Parkers: Volkswagen Golf Mk5 (2004-2009) used review

• Timing belt changes (chain on 1.4 TSI and FSI)

  All engines

  Most engines use a timing belt due every four years or 70,000 miles, and it’s a fiddly job so it’s sometimes skipped. The 1.4 TSI and FSI use a chain instead, which can rattle when worn.

  At the viewing: Ask for an invoice for the last belt change. On a TSI or FSI, listen for a rattle at start-up.

  Source: Parkers: Volkswagen Golf Mk5 (2004-2009) used review

• Turbo wear (1.9 and 2.0 TDI)

  1.9 and 2.0 TDI diesel

  High-mileage diesel turbos wear out, which makes the car sluggish and can cause smoke or a whistle. Replacing a turbo is expensive.

  At the viewing: Watch for smoke and listen for whistling when you accelerate hard.

  Source: Parkers: Volkswagen Golf Mk5 (2004-2009) used review

• Rust on the wings, sills and tailgate

  All engines

  Rust starts where the plastic arch liners rub through the paint, and on the sills and around the tailgate badge.

  At the viewing: Look at the wheel arches, sills and tailgate, and check the MOT history for corrosion.

  Source: Parkers: Volkswagen Golf Mk5 (2004-2009) used review

• Air conditioning failure

  All engines

  Air con on older cars can fail anywhere from a pressure switch to the compressor or condenser, which can cost hundreds.

  At the viewing: Make sure the air con blows cold, and listen for noises when you switch it on.

  Source: Parkers: Volkswagen Golf Mk5 (2004-2009) used review

• DSG automatic

  DSG automatic

  A neglected DSG can change slowly or jerkily, lurch when pulling away or rumble when stopped. It has its own oil that needs changing.

  At the viewing: Drive in stop-start traffic and pull away several times. Ask for proof of DSG oil changes.

  Source: Parkers: Volkswagen Golf Mk5 (2004-2009) used review

Questions to ask the seller before buying a 2004 Volkswagen Golf diesel

Ask before you travel to see it. A seller who knows the car will have answers, and receipts.

1. Has the clutch or flywheel been replaced, and is there an invoice?
2. When was the timing belt last changed, and is there an invoice?
3. Has the turbo been replaced, and has the oil been changed on time?
4. Any recent work on the suspension arm bushes and joints? (Flagged at MOT 2.2× as often on the 2004 Volkswagen Golf diesel as on other cars the same age.)
5. Any recent work on the drive shaft (cv) joints? (Flagged at MOT 2.6× as often on the 2004 Volkswagen Golf diesel as on other cars the same age.)
6. Any recent work on the sub-frame? (Flagged at MOT 2.2× as often on the 2004 Volkswagen Golf diesel as on other cars the same age.)