Hi all, I posted a while back with boost / turbo issues. After lots of help it came down to a faulty boost pressure regulator (n75) and some vacuum pipes with holes in them.
However someone suggested I got a compression test done, and after 2 compression tests the garage finally told me that Cyl 2 was misfiring. I can believe that as the car was becoming more and more jerky - so I paid out the 700 euro for them to replace the injector.
Problem is that car was driving fine for 150 miles, then all of a sudden it became very jerky. Its clearly felt upto 3000 revs, if you keep the revs above that the car drives fine, plenty of power and doesn't enter limp mode.
The car jerks so much that the EPS light come (the orange triangle thingy)
The car is 2002 passat 1.9 TDi 130bhp AWX enigne.
I know the codes were cleared from last time so I've stuck the car on vag-com again and it showed:
2 Faults Found:
18075 - Valve for Pump-Jet: Cylinder 2 (N241): Electrical Malfunction
P1667 - 35-10 - - - Intermittent
16686 - Cylinder 2 Misfire Detected
P0302 - 35-00
The garage don't believe that the cylinder could be faulty after 150 miles so want to charge me for 'lab time' to establish the problem. That ain't going happen so hopefully someone has an idea to the problem?
I just read another post about a judderey car - suggesting to change the fuel filter - is that something worth looking at? it was done around 12k ago so due a change anyway I guess....
thanks for your help everyone.
Richard
Moved over from Discussion and subject line tweaked.
Edited by Pugugly on 20/09/2008 at 17:56
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I suggest you also post this here :
www.vwaudiforum.co.uk/forum/forumdisplay.php?f=113
Regards Peter
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This could be a faulty replacement injector, or dare I say they did not change it at all and use injector cleaner and the fault cleared. There is a fare bit of labout time in changing and injector on these PD engines. However the fualt code report an electircal problem, injector, cable harness, the connector which is in engine oil. Regards Peter
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A fault which is becoming common as the PD engines age is a faulty wiring loom to the injectors. This runs in a plastic channel inside the cylinder head.
It causes an intermittent connection to one or more injectors which makes the engine misfire. It's relatively cheap and easy to replace. Running wires and putting connectors inside an engine was not a good idea.
659.
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I have experienced the same problem and wd40 temporarily aleviates the issue but then after a few hunded miles when the engine gets hot it starts missing again. I think water may have got in as i ran the fuel tank very low.
Could you help with advice fitting the loom as it is a solid plastic piece that needs to feed in from the back of the engine and without removing the engine head i am wondering how this may be possible ? do i need to break the plastic loom so it can bend in ?
any advice would be greatly appreciated
thanks
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Please explain the use of WD40 and where you think the water is. Regards Peter
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water just a theory as i ran my fuel tank very low and possibly had water at bottom (180k on clock).
i applied the wd40 onto the joints from the loom to the injectors across all injectors
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The fuel filtration system on the VAG PD diesels will not allow water into the system. Start by draining the main filter at the tap provided and examine the resultant after it has settled out. There is also a strainer in the tank.
The injector loom is flexible enough to fit in situ on the AWX. It goes in more easily if you warm it first. For checking intermittency, I use an AVO to check for continuity at the big connector. Wobbling the wires at the injector connectors will usually show up any problems - the actual cables themselves don't seem to fail, neither do the injector solenoids.
It might be worth doing a check on the numbering - the glowplug numbering for VAGCOM failure logging is reversed (ie Cyl 1 is actually Cyl 4) and this might also apply to the injectors, although I've never checked it. I don't think the person who wrote the software knew anything about engines.
659.
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I have dained abnd replaced fuel filter, also replaced the maf which did not solve but did improve my turbo when not missing.
the flexibilty did make me nervous, but if you thing it will feed in from the back then i take your advice.
in terms of the tests you refer that is a little above my head, i just thought it must be corrosion/wear on the joins to the injectors as wd40 cured the missing.
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Don't worry about running the fuel low, the fuel is always picked up from the same place (the bottom) regardless of fuel level, and water always puddles at the bottom (if present). Any water would be picked up by the filter over it's life. If it gets saturated, will block.
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can anyone reccomend the mest method for warming the loom to make it more flexible
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gmt
The old loom will break coming out; but the new one will bend - even cold. Just warm it a little with a hairdryer etc. if you must - don't go mad.
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Hi all,
thanks for help with my car. After the garage replacing the injector it still misfired intermittenly. I read the above about the wiring loom and insisted they changed it (garage were relucent stating they have never changed one before!)
The car has been fine now for over 3000 miles so pretty confident that the misfire has been resolved. Although it hasn't fixed the smoking on startup (running on another thread)
I was wondering if your car was throwing out a grayish / blue smoke on cold startup (ie stationary for over 4 hours) ?
thanks again everyone
Richard
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Hi all,
had one alst question really - I'm still not sure if the injector is working correctly. The car is driving fine and has plenty of power (although the smoke issue is still bugging me - see other posts)
Whilst looking at the smoke problem I measured the injector workings with vag-com and got some results I don't understand (nothing new there then!)
can aunyone interperate these results for group 13....
I measured from a warm start on group 13 and reved it up to 1500. I saw that Cyl 2 was always in the -1 to -3 reading when the other cyl were all in the positive.
Heres the results:
www.traceyourfamily.co.uk/car/group13.jpg
It was cylinder 2 injector that was replaced by the garage due to a misfire.
cheers all
Richard
Edited by Richard_Gomm on 27/10/2008 at 22:42
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It's about what I'd expect to see if you put one new injector into an old engine. Your curves illustrate just how good the other three are - I've no doubt if injector 2 was original you would have had 4 closely matched curves. I wouldn't worry about it. (Delphi please note, it is possible to match injectors so they don't need coding).
659.
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659 - not sure I get you on that one. That graph shows the readings after the new injector was put in. It shows completely opposite to the other 3 for the values...?
you say the other curves show how good the other injectors how - are you saying that they are bad and if I put new ones in all 4 curves would be the same??
Does the difference in the readings matter??
What are those readings showing, should I be looking at replacing all the other injectors soon?
cheers - RG /21
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Richard
Those are smooth-running correction figures; measuring how much the ECU has to adjust each injector's flow to keep each half-revolution of the engine occurring in exactly the same period of time.
Plus-or-minus 5% is the limit; anything less than that indicates the effectiveness of each injection. Your brand-new injector is simply working/atomizing better than the old ones - no surprise there - so is getting a tiny bit less fuel each squirt to compensate.
This is a zero-sum game; the percentages will always add up to zero. Without the, temporary, effect of your new injector; the percentages would be within the 1% band - very good.
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screwloose - thanks that made perfect sense, I must have been having an off moment. by the way thanks for the help back at the beginning of this - wished we'd come up with the wiring loom before I payed for the injector to be replaced! Still better fixed than not.
do yo have thoughts on the white smoke? thats the only thing left with the car now, once thats fixed it's a fantastic car..
cheers
Richard
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Richard
Still thinking about that.
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I have an 01 Passat, which has done 160,000 miles. Recently started juddering once the engine was warm. Usually about 7 to 8 miles into a journey, but ok if revs were kept above 2500.
Been in the garage today, diagnosed a misfire, said one of the injectors was faulty. They have put in a new wiring loom which they think has done the trick, if not i will need a new injector. That is £414 from VW alternatively it can be reconditioned.
Any views on reconditioning?
And if one injector (out of 4) is dodgy, are the others likely to go?
The wiring loom and labour and diagnostics was only £149. But don't really want to throw good money after bad. Wondering if a new car might be the answer!!!
any views for a poor helpless girly appreciated!!!!
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PD injectors are very reliable and will normally outlast an engine. The wiring loom is the weak point - thankfully easy to change and fairly cheap. I would expect the replacement loom to solve the problem if there are no other faults.
659.
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Hi Folks,
Have just resolved a similar problem with my 02 plate 1.9TDi Passat. An intermittent misfire problem which was getting progrssively worse finally ending in a complete loss of power (with EPS fault lamp activating too). Luckily my garage had heard of similar problems with faulty wiring loom. They replaced this for a cost of £120 and car is running fine once more. Could easily have been mis-diagnosed at great expense.
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My sons Fabia had Misfire when warm MIL and EPS lights on, misfire not as bad past 3000rpm.
VCDS showed
2 Faults Found:
18075 - Valve for Pump-Jet: Cylinder 2 (N241): Electrical Malfunction
P1667 - 35-10 - - - Intermittent
16686 - Cylinder 2 Misfire Detected
P0302 - 35-00
Also ABS fault, low bat fault.
After reading post above inspected loom & plugs for injectors under rocker cover could see no problems, used the pointed end of circuit tester probe to close down gap on female part of connecter @ loom plugs.
This has fixed the issue without replacing anything.
May not work for every one but worth a go.
Hope this helps.
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