Have a 2005 1.9PD. 145K miles.   Over the last while it has developed a horrific judder at idle and while accelerating.

I had thought it could be the EGR valve, took it off and cleaned it a few months back which did seem to make it a bit better but over the last couple of weeks it has got much much worse.  Now can't use 5th gear at all, can't accelerate in 4th.  

 

Oddly it can be occasionally but not reliably cleared by switching the engine off and on again.   So drive 20 -40 miles switch it off/on cleared and car good as ever.  

 

Took it into a garage who had a look at VCDS and said there was an injector fault, £700 to replace.  Can't afford that.  

 

Any other thoughts before I go mad.  

It kind of does sound like an injector fault if it judders at idle. There are some other things to check though to rule them out.

 

Check all the vacuum pipes are secure and not damaged. They come from a small box at the top left of the engine bay.

 

Is there any sign of fuel leaking from the filter housing?

 

Are the joints on the boost pipes secure? Signs of black oil around the joins can indicate a poor seal.

 

Phil

Is it rough and noisy, or just rough?

 

In the first case it could be the DMF.

Rough and noisy,  bit like a 1930's tractor engine.  Any idea why it clears on restarting once warm(ish)? I drove south london to milton keynes the other day, first 40 miles I couldn't get over about 55mph and thought I was going to be shaken to pieces, rolled off at a junction got to the lights , off / on a couple of times then it was fine and the rest of the way was entirely normal?  

Well had a good look round the engine bay this evening, all the pipes are secure, the only sign of oil mist is around the EGR valve which seems to have accumulated on the outside again after cleaning.  No signs of any leaking fuel.  

 

Does it vibrate and judder violently when trying to accelerate from low engine speeds, and not as much when the engine speeds are higher?

 

Yes. Though it's not entirely clear given the changing road noise etc.  

 

Without a clear diagnosis ​I suspect it's beyond my resources to fix and see something else fail.  Is there a way to temp disable the EGR valve and just see if that does anything or was it just co-incidental that cleaning that previously helped?  

Common failure on the 1.9 PD is the injector wiring loom, this will show up as injector failure.dropping a cylinder or two when in fault mode.

 

Wiring failures cause injector(s) to be tripped out - possibly reset for a while on startup. The loom sits in a hostile hot and oily environment inside the engine.

 

 

 

 

Wont be DMF as that wont fix itself by turning off and on again

Edited 8 August, 201510 yr by bigjohn

Covered on:-

 

https://www.dropbox.com/s/rpqeeksws4v57qx/VW%20Bora%201.9tdimk4.pdf

Cheers BigJohn.   Got to be worth a try, I've picked up a wiring loom from TPS for £70 so just got to get up the nerve to take the thing apart now.  These jobs always seem easier to start than to finish.  

I got up the guts to change the loom last week.  We are fixed    have done 200 miles since then , mix of 5 mile round town trips and a 140 mile a road run and no more judder.    Fuel econ seems better as well at almost 70mpg indicated on the long run! 

 

Took me about 5 hours , couple of sticky points where I sat and stared at it for 30 mins.  One bolt on the EGR valve wouldn't move, sorted using the wrong size allen key at an angle in a do or die moment.  turns out the hollow was part full of hardened nutlock  .  a little bracket at the front of the engine and some air-filter screws had corroded and had to be drilled out.    

 

Getting the loom itself out / in was straightforward but disassembling all the bits to get to it took forever.  If your more competent than me then it's probably only a couple of hours.  

 

Anyhow a massive than you to you all for your suggestions and to the chap on the counter at TPS Crawley for some sage advice and encouragement.   

I got up the guts to change the loom last week.  We are fixed    have done 200 miles since then , mix of 5 mile round town trips and a 140 mile a road run and no more judder.    Fuel econ seems better as well at almost 70mpg indicated on the long run! 

 

Took me about 5 hours , couple of sticky points where I sat and stared at it for 30 mins.  One bolt on the EGR valve wouldn't move, sorted using the wrong size allen key at an angle in a do or die moment.  turns out the hollow was part full of hardened nutlock  .  a little bracket at the front of the engine and some air-filter screws had corroded and had to be drilled out.    

 

Getting the loom itself out / in was straightforward but disassembling all the bits to get to it took forever.  If your more competent than me then it's probably only a couple of hours.  

 

Anyhow a massive than you to you all for your suggestions and to the chap on the counter at TPS Crawley for some sage advice and encouragement.   

 

Great stuff !