2003 Volkswagen Caravelle: common problems and MOT failures

What goes wrong more than usual on a 2003 Volkswagen Caravelle?

Parts flagged at MOT more often on the 2003 Volkswagen Caravelle than on all cars registered in 2003.

• Steering rack inner joints3.8× usual
  Volkswagen Caravelle

  12.8% All 2003 cars

  3.4%

  Failed outright at MOT: 0%, against 0% of all 2003 cars. The rest were advisories or minor defects.

  Rough price £100–£450 our estimate

  At the viewing: On a straight road the steering wheel should sit straight. Listen for knocks when turning, and check the steering feels even.

• Flexible brake hoses2.2× usual
  Volkswagen Caravelle

  13.1% All 2003 cars

  5.9%

  Failed outright at MOT: 3.5%, against 1.2% of all 2003 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.

• Steering rack3.8× usual
  Volkswagen Caravelle

  6.1% All 2003 cars

  1.6%

  Failed outright at MOT: 4.1%, against 0.9% of all 2003 cars. The rest were advisories or minor defects.

  Rough price £100–£450 our estimate

  At the viewing: On a straight road the steering wheel should sit straight. Listen for knocks when turning, and check the steering feels even.

• Ball joint dust cover2× usual
  Volkswagen Caravelle

  9.3% All 2003 cars

  4.7%

  Failed outright at MOT: 3.7%, against 1.8% of all 2003 cars. The rest were advisories or minor defects.

  Rough price £60–£150 (one joint) ClickMechanic

  At the viewing: Listen for knocking over bumps and check the rubber boots behind the wheels aren't split.

• Seat belts2.8× usual
  Volkswagen Caravelle

  4.7% All 2003 cars

  1.7%

  Failed outright at MOT: 1.1%, against 0.6% of all 2003 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 smoothly.

Common 2003 Volkswagen Caravelle MOT failures and advisories

The share of 2003 Volkswagen Caravelle MOT tests where testers flagged each area, as a fail or an advisory. Rough prices are typical independent-garage costs.

• Brakes
  47% 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.

• Suspension
  47% 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.

• Lights and electrics
  36% 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
  29% 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.

• Oil and fluid leaks
  21% of testsRough price £80–£600

  At the viewing: Look under the engine and on the ground where the car is usually parked for fresh oil or fluid.

• Steering
  16% of testsRough price £100–£450

  At the viewing: On a straight road the steering wheel should sit straight. Feel for play or knocking when turning.

Known faults on the 2003 Volkswagen Caravelle

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.

• Fire-risk and handbrake recalls

  All engines

  Recalls covered a fuel pipe and fuel pump cover bolts that could cause a fire, a handbrake that could release by itself (over 8,000 vans), a steering rack that could come loose, second-row seat backrests and cooling fan wiring.

  At the viewing: Ask a VW dealer to check the VIN for outstanding recalls.

  Source: Haynes: VW T5 common problems (2003-2015)

• Blocked EGR valve

  Diesel

  A blocked EGR valve causes stalling, judder and hunting revs. The fix is a new EGR valve and cooler.

  At the viewing: Let it idle and listen for uneven revs, and check for warning lights.

  Source: Haynes: VW T5 common problems (2003-2015)

• Oil leak between engine and gearbox

  All engines

  Badly threaded flywheel bolt holes can let oil leak where the engine meets the gearbox. Fixing it means taking the gearbox off.

  At the viewing: Look under the van between the engine and gearbox for oil.

  Source: Haynes: VW T5 common problems (2003-2015)

• Hard starting (camshaft sensor)

  All engines

  A failing camshaft position sensor can make it hard to start.

  At the viewing: Start it from cold.

  Source: Haynes: VW T5 common problems (2003-2015)

• Exhaust whistle or fumes in the cab

  Diesel

  A failed exhaust manifold gasket causes a whistle and can let fumes into the cab.

  At the viewing: Listen for a whistle under load and sniff for fumes.

  Source: Haynes: VW T5 common problems (2003-2015)

• False sliding door warning

  All engines

  The door switch can be out of adjustment, so the van thinks the sliding door is open.

  At the viewing: Shut all doors and make sure no warning shows.

  Source: Haynes: VW T5 common problems (2003-2015)

Questions to ask the seller before buying a 2003 Volkswagen Caravelle

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

1. Have all the recalls been done? Can a VW dealer confirm from the VIN?
2. Any recent work on the steering rack inner joints? (Flagged at MOT 3.8× as often on the 2003 Volkswagen Caravelle as on other cars the same age.)
3. Any recent work on the flexible brake hoses? (Flagged at MOT 2.2× as often on the 2003 Volkswagen Caravelle as on other cars the same age.)
4. Any recent work on the steering rack? (Flagged at MOT 3.8× as often on the 2003 Volkswagen Caravelle as on other cars the same age.)
5. Can I see the service history and receipts for any big jobs?