I need help to fix issue with my Skoda Octavia 1.9 TDI 2005 model. Clocked 1,60,000 kms. 

 

ECM was changed and programmed before 1 year as the factory fitted one was burnt. Car was without any issues. Timing belt kit was replaced before 6 months and it didn't create any issues after replacement.

 

There has been misfire, engine vibration, reduced fuel efficiency and power. Idle RPM has been very low (550-600 RPM) when the misfiring issue started. 

 

I recently experienced the new issue of engine stalling while driving in slow speed. Injectors were serviced, Fuel pump is calibrated. No starting problem. Starts within single crank. If engine switches while driving, it takes a few minutes to start again. I suspect that it has got something to follow with Crankshaft position sensor. I removed the sensor connector and it shows 1199 ohms between Pin 1 and 2 on the connector which leads to the sensor. On the female connector, there is no voltage supplied between the positive and ground. How does the car start when I connect the connector and when there is no power supply? Wiring harness has no damage. Earlier, there was check engine and glow plug light lit on the dashboard when the engine stalled but it disappeared automatically. What should I do next? 

Check the vacuum system for split rubber hoses and the solenoid valve block, also turbo actuator operation.  If the turbo isn't moving to the high boost position with vacuum the engine will stall easily and perform poorly.

 

There could also be a loose female spade connector on the injectors, a quick check is to remove the wiring harness screw plug on the end of the engine by the tandem pump and measure the resistance of each injector, they should all be the same.  Of course this is a static check and doesn't account for vibration during engine operation.

Hi MicMac, 

 

Thanks for your inputs. 

I have already replaced the vacuum hoses. I would do the remaining checks advised by you. 

 

Regards, 

Balaji

Jaldi jaldi!

Edited 6 May, 20215 yr by MicMac

I have checked the injectors and the connectors. It seems to be fine. There is 0 V on positive terminal and signal of crankshaft sensor. Ground shows 12 V. Is this due to faulty sensor or ECM? 

When the engine is running, is it smooth and revs freely without any strange noises?

 

Just wondering if the camshaft is worn

There is misfiring and I could hear the knocking

The RPM is zero while cranking and it's around 600 in idle

You might want to remove the camshaft cover and inspect the camshaft lobes for excessive wear, usually as a result of high mileage or using incorrect engine oil.

 

Disconnect the air intake at the filter and listen for the tell-tale sound as shown in many youtube videos, search "VW 1.9 bad camshaft".

 

Have you checked the EGR for soot build-up that will cause a restriction to air flow?

Edited 11 May, 20215 yr by MicMac

EGR cleaned, Airflow sensor cleaned. I did decarbonizing using hydrogen liquid and gas recently. Nozzles were serviced. RPM is normal. It show 600 because the needle rests below zero rpm. The latest scan result shoes P1248 error. I have attached the scan result images. The fuel supply is erratic, the graph is evident. When accelerating, fuel consumption decreases (as per scan tool readings) and when deceleration, it increases. At idle injection quantity is 3.4 to 4.8 mg but suddenly shoots up to 22 mg. No air bubble in fuel line. When I advance timing, car starts in one crank but later it takes 3-4 cranks. Car jerks while releasing accelerator. Both at slow speed and high speed fuel supply is intermittent and no response to acceleration at times. Timing is inconsistent. I suspect it to the problem with ALH Pump Pressure Valve. Please advise.

The fault code P1248 got fixed after setting the Injection Pump Timing with the help of VCDS. I bought a 50 ml syringe at the pharmacy and checked the solenoids N75, N18, EGR valve and Wastewater/Turbo Actuator. N18 was stuck. I opened it and cleaned with carb cleaner. It works fine now. EGR valve open on applying vacuum using the syringe. N75 is also good. Turbo Actuator doesn't hold vacuum. Turbo is recently serviced. Replaced the actuator and it solved the low boost and Engine Stalling