One of the first things Routan owners often consider is the engine. The 2009 SEL model, like the one mentioned in the original post, came with the 4.0L engine. While the original author muses about preferring the 3.8L in retrospect (found in the S and SE models), both engines have their pros and cons. The 3.8L engines of that era were known to have oil consumption problems in some cases, although it wasn’t universally prevalent. However, the 3.8L engine generally proves to be more reliable and easier to service than the 4.0L. Despite EPA ratings suggesting similar fuel economy, the 4.0L tends to be less fuel-efficient in real-world driving.
From a maintenance and repair standpoint, the Routan can be more expensive compared to other minivans, as the original author notes. This is a crucial point, especially as these vehicles age. Many owners find themselves keeping their Routans running due to depreciation making resale less appealing. Driving it “until the transmission craps out again” and then scrapping it might resonate with those familiar with the ownership experience.
When considering a minivan from this era, exploring alternatives like Toyota or Honda is wise. Even stepping back a couple of model years to a 2006 Toyota Sienna might offer greater reliability and lower maintenance costs compared to an early VW Routan (2009-2010). If you’re set on the Chrysler platform, the Dodge or Chrysler versions of the minivan might be easier to maintain, primarily because accessing the Routan’s computer system for diagnostics and repairs often requires VW-specific tools like the STAR Scan, potentially limiting repair options to VW dealerships or specialized shops.
It’s worth mentioning that significant improvements were made to the Routan starting from late 2012 models onwards. These later models benefited from larger brakes and addressed initial issues with the 3.6L Pentastar engine that was introduced in the 2011 refresh of the 5th generation Chrysler minivans (including the Routan). The early 3.6L Pentastar engines sometimes suffered from cylinder head problems, which could be costly to repair if not covered by warranty.
Now, let’s delve into some common specific problems frequently reported by 2009-era VW Routan owners:
1. Coolant Leaks at the Y-Diverter Valve
A prevalent issue is coolant leaks stemming from the plastic Y-diverter valve. This plastic component is prone to cracking, typically around the 40,000 to 50,000-mile mark. While the part itself isn’t excessively expensive, the leak can be subtle initially and drip coolant onto the EGR valve situated below. This coolant exposure can lead to EGR valve failure, significantly increasing repair costs. A faulty EGR valve can also cause stalling issues, particularly after cold starts. The silver lining is that aftermarket aluminum Y-valve replacements are available, offering a permanent fix when paired with quality hoses and clamps.
2. Inadequate Brakes and Warped Rotors
The brakes on the early Routan models are often considered undersized. While not inherently a safety hazard, they are prone to warping due to heat buildup. Some owners report needing front brake replacements as frequently as every 12,000 to 20,000 miles initially. Upgrading to slotted or drilled rotors can extend brake life to around 40,000 miles. A more permanent solution involves upgrading to the larger brakes introduced in the 2013+ models. However, this upgrade is generally only feasible on SE, SEL, and SEL Premium models equipped with 17-inch wheels. The upgrade entails replacing pads, all four rotors, dust shields, and dual-piston brake calipers on all wheels, incurring a substantial cost. The base Routan S model with 16-inch wheels is generally not compatible with this brake upgrade without also changing wheels and tires.
3. 6-Speed Transmission Longevity
The 6-speed Chrysler transmission in these Routans typically has a lifespan of around 100,000 to 120,000 miles. Replacement at a dealership can be a significant expense, often quoted around $4,500. Opting for an independent shop and sourcing parts yourself might reduce the cost to the $3,000 to $3,500 range. Rebuild options may also be available, but their cost-effectiveness should be carefully evaluated.
4. Wheel Bearing Hub Assembly Failures
Wheel bearing hub assemblies are another known weak point. This issue was significant enough that Chrysler/VW extended the warranty on these components, although that extended warranty period has long expired. Aftermarket options are available and seem to offer improved longevity. However, replacement still costs around $200 per wheel, and diagnosis can be challenging, even for experienced technicians, if they aren’t specifically familiar with this common Routan issue.
5. Electrical Gremlins
Electrical issues are a frequent complaint, often manifesting as problems with power sliding doors and power-folding third-row seats. These “electrical gremlins” can be intermittent and frustrating to diagnose and repair.
6. 4.0L Engine Timing Belt
For 2008-2009 SEL and SEL Premium models equipped with the 4.0L engine, the timing belt is a critical maintenance item. This engine is an interference engine, meaning that timing belt failure can cause severe engine damage. Scheduled timing belt replacement is required every 102,000 miles and typically costs between $600 to $800. The 3.8L engines in the S and SE models utilize a timing chain, which generally does not require scheduled replacement and is considered more durable.
Conclusion
While the VW Routan offered some appealing features, particularly its European styling and minivan practicality, potential buyers and current owners need to be aware of these common problems. The early models, especially those from 2009-2012, have a history of coolant leaks, brake issues, transmission concerns, wheel bearing failures, and electrical problems. The 4.0L engine also adds the maintenance cost of timing belt replacement.
If you are considering a minivan in this category, carefully weigh the potential maintenance costs and reliability concerns associated with the VW Routan against alternatives like Toyota Sienna or Honda Odyssey. While later Routan models (2013-2014) addressed some of these issues, the earlier years require diligent maintenance and proactive attention to these common problem areas. For current owners, staying informed about these problems with your VW Routan is the first step in preventative maintenance and managing repair costs.
