KU57 MLZ - Injector issues I think, No fault codes. Misfire/hesitation and Intermittent smoke. (Pic Heavy)

[amk2vr6]

Is there any way I can edit my posts Mods?

[amk2vr6]

Ill add all of the images again here to keep the thread in line...

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

[amk2vr6]

 

 

 

[amk2vr6]

Can't believe I dont that! I've ruined the thread now... 

[Plantman]

Also, just a quick thought. What boost pressure should the car be requesting if it has been remapped?

Mine is asking for 2500mBar, so minus atmospheric pressure actually 1.5bar. That's 21.7psi which is an awful lot! My old Audi S4 only used to pull about 18psi!!

 

Can anyone have a look themselves and compare to my log on the previous page?

 

Thanks

In VCDS I see my boost hit 2606 IIRC....

Different engine slightly of course.

[amk2vr6]

In VCDS I see my boost hit 2606 IIRC....

Different engine slightly of course.

 

Thank you! So map is requesting the correct boost then.

 

What next to try... I'm sort of stumped here.

[Plantman]

Yea, and as you can see injector 3 is almost getting out of spec (values of way over 2.00)...so wonder if you have a knackered injector?

 

You could swap injectors and see if the fault moves with it....or borrow another known working injector to test with....

 

"Usually when the correction factor gets over =/- 1.0 mg/stroke you start to notice operational issues."

Edited 8 May, 2014 by Plantman

[Plantman]

https://sites.google.com/site/1810martin/vcds-and-pd-tdi-engine-health-check

 

All 4 injectors should have similar figures as close to zero as possible.

E.g.

 

13, 1, Injection Quantity, Deviation Cyl. 1.  -0.28 mg/str

13, 2, Injection Quantity, Deviation Cyl. 2.  -0.49 mg/str

13, 3, Injection Quantity, Deviation Cyl. 3.  0.56 mg/str

13, 4, Injection Quantity, Deviation Cyl. 4.  0.21 mg/str

 

If one injector is well out of specification compared to the others it could be faulty or it could be a faulty cam lobe.

If all figures are all over the place it suggests worn camshafts.

It is hard to tell if an injector oddity is due to an injector fault or a camshaft fault.

Apparent multiple injector faults are usually worn camshafts.

Edited 8 May, 2014 by Plantman

[amk2vr6]

Thanks Plantman! I've read that page. Quite a lot of information there, even if it is for passats its still relevant. Read the ECU remap stuff too, it taught me a bit.

 

Cam problem then it looks like on that diagnosis. Only thing that goes against that is the fact it comes and goes. Surely a worn cam would be a constant?

[amk2vr6]

And it does come and go. You can watch the measuring blocks, and cylinder three go out to +2 - +3 itll start rocking and missing for maybe 5-10 seconds, and then it'll come right back inline with all values +/- 0.3 for 5-10 seconds...

[amk2vr6]

Does anyone know - Isn't cylinder 3 used in line with the Crank sensor? I've read it somewhere but can't find the page now.

[amk2vr6]

Yea, and as you can see injector 3 is almost getting out of spec (values of way over 2.00)...so wonder if you have a knackered injector?

 

You could swap injectors and see if the fault moves with it....or borrow another known working injector to test with....

 

"Usually when the correction factor gets over =/- 1.0 mg/stroke you start to notice operational issues."

 

Sorry I didn't see this post. I have 3 spare injectors that came with the car. I have swapped one already, and it got slightly better, but overall no difference.

[Plantman]

So the values were the same on that injector when replaced? Least that eliminates an injector fault I guess. Odd you had them come with the car. Guess the previous owner was trying to sort this issue too?

 

Injector seals shot?

 

Injector loom ok? Think this was mentioned already. Being bathed in oil they can soon produce faults, 'miss fires' and the like.  <---- Edit, just re-read you have already had that replaced!

Edited 8 May, 2014 by Plantman

[Plantman]

Does anyone know - Isn't cylinder 3 used in line with the Crank sensor? I've read it somewhere but can't find the page now.

http://www.volkspage.net/technik/ssp/ssp/SSP_316.pdf

 

that the one on page 20?

 

http://www.fixya.com/cars/t6734476-crank_sensor

 

http://wiki.ross-tech.com/wiki/index.php/16706/P0322/000802

Edited 8 May, 2014 by Plantman

[AP Automotive]

A few possibilities could be, injector loom, injector, crank sensor.

 

I had one the other day, intermitant non start, until complete failure. Broken crank sensor wire and faulty injector loom.

Crank sensor pain to fit, so check wiring first.

[amk2vr6]

So the values were the same on that injector when replaced? Least that eliminates an injector fault I guess. Odd you had them come with the car. Guess the previous owner was trying to sort this issue too?

 

Injector seals shot?

 

Injector loom ok? This this was mentioned already. Being bathed in oil they can soon produce faults, 'miss fires' and the like.

 

Yes the values where the same or very similar. Only difference being that it seemed a bit better. Look at the pics above, the injector I removed had a couple of nicks in the injector seal. The one I replaced it with had perfect seals, but I had to reuse the clamp bolts which are stretch (use once) bolts.

One of the bolts on cylinder 4 is rounded off which tells me the bolts have been used and reused a few times.

 

I have a full set of injector seals and bolts that will be fitted this weekend. I will adjust Torsion to +0.5, and re adjust rocker clearance with new plungers too, as well as making sure injectors are seated correctly without damaging seals.

 

I have a receipt for injector loom from September that came with the car, and has done barely 1000 miles since, however, the wires look hard and brittle, which makes  me think it wasn't fitted and was possibly returned. I will be checking resistance of wires back to ECU as I now have a pin out.

[amk2vr6]

A few possibilities could be, injector loom, injector, crank sensor.

 

I had one the other day, intermitant non start, until complete failure. Broken crank sensor wire and faulty injector loom.

Crank sensor pain to fit, so check wiring first.

 

Hi, thanks for the reply.

 

Did it flag a code on VCDS/Vagcom?

 

And did you remove the box to change the sensor ring too, or just the external sensor in the bell housing?

[AP Automotive]

Hi, thanks for the reply.

 

Did it flag a code on VCDS/Vagcom?

 

And did you remove the box to change the sensor ring too, or just the external sensor in the bell housing?

 

No fault logged for crank initially, only after disturbing the wires to test did it log on diagnstics as signal fault.

 

Sensor was not faulty, sensor ring was not faulty

[amk2vr6]

No fault logged for crank initially, only after disturbing the wires to test did it log on diagnstics as signal fault.

 

Sensor was not faulty, sensor ring was not faulty

 

Sorry so what part of it was? What was replaced?

 

Thanks again.

[Plantman]

Spooky, almost matches your issue!

 

http://www.vwaudiforum.co.uk/forum/showthread.php?114825-2-0-tdi-bmn-bkd-engine-idle-misfire-judder-PLEASE-HELP!!!&s=3700a2415ac5aed15be136f4533d7394

[Plantman]

Been through VCDS and the measuring blocks to make sure all sensors are reading correctly (e.g. at ambient when car is cold)?

 

Tried unplugging say coolant sensor and the fuel temp sensors to see if behaviour improves?

[amk2vr6]

I know, if it wasn't for it being a different vehicle I would have thought I bought that car! My Flywheel and clutch have just been changed too! haha.

 

I've read that, and it was never updated to show the result :( 

 

I've spent days scouring the net and nothing is conclusive. Only thing I keep coming back to is Crank sensor.

 

Do you know if the 2.0 TDI can be compression tested as glow plugs are inside head?

[Plantman]

Don't know the answer to that one sorry. Poss not it seems when you check the web internet....

 

http://www.volkswagenforum.co.uk/f33/2005-golf-gt-tdi-misfire-problem-11501.html  <- post #6

 

http://www.myturbodiesel.com/threads/vw-audi-2-0l-tdi-bmn-bkd-engine-misfire-judder-fix.4728/  <- post 10

[Plantman]

http://forums.tdiclub.com/showthread.php?t=331796 - BKD engine wont start after injectors swap >I know yours isn't a BKD <

 

PS: I would try posting on this forum above. The chaps across the pond are very good at the derv tech.

 

 

And......also try a post here too, if you have not already:

 

http://www.audi-sport.net/vb/forum.php

Edited 8 May, 2014 by Plantman

[amk2vr6]

Wow, nice links thanks again for your help.

 

Here's the pic of the injector hole with a damaged seat from the first link you supplied -

 

 

And here is the best PIC I've got of the suspect cylinder on mine -

 

Edited 8 May, 2014 by amk2vr6