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Thread: My first project

  1. #661
    Join Date
    May 2014
    Location
    Shropshire
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    Right I got the VAGCOM hooked up!


    Saturday, 02 March 2019, 09:57:36.
    Control Module Part Number: 038 906 019 KJ
    Component and/or Version: 1,9l R4 EDC 0000SG 5256
    Software Coding: 00002
    Work Shop Code: WSC 06403
    VCID: 69A53EA70061
    5 Faults Found:
    17849 - EGR Valve (N18 ): Open Circuit or Short to Ground
    P1441 - 35-10 - - - Intermittent
    19561 - Shareware Version. To Decode all DTCs
    P3105 - 35-10 - Please Register/Activate - Intermittent
    18027 - Shareware Version. To Decode all DTCs
    P1619 - 35-00 - Please Register/Activate
    18058 - Powertrain Data Bus: Missing Message from Instrument Cluster
    P1650 - 35-00 - -
    17932 - Shareware Version. To Decode all DTCs
    P1524 - 35-00 - Please Register/Activate

    so..
    1) EGR hasn't been mapped out yet, no news to me.
    2) Valve for Intake Manifold Flap (N239): Open or Short to Ground, again no surprise
    3) Glow plug relay short (Now we're getting somewhere)
    4) Missing Message from Instrument Cluster - makes sense, I have no mk4 Instruments
    5) Fuel pump relay short, again adds up as I have no lift pump

    So perhaps plugs to be investigated?
    Also on start up these were the sort of readings coming from the injectors, along with a cloud of white smoke which stank of diesel
    injectors.JPG
    Last edited by fuus; 03-03-2019 at 06:58 PM.

  2. #662
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    May 2014
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    Next to try and find out how to diagnose this glowplug setup. Where's a monkey when you need one
    Pretty sure this 103 is the glow relay so might bench test it
    20190302_121430.jpg
    20190302_121630.jpg

  3. #663
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    May 2014
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    Welll that little issue is sorted. One rogue wire. This hasn't sorted my misfiring / starting issues though. Also another code has appeared which I'll upload in a minute

    53364303_1990645294563024_8706563913526804480_n.jpg

    5 Faults Found:
    17849 - EGR Valve (N18 ): Open Circuit or Short to Ground
    P1441 - 35-10 - - - Intermittent
    19561 - Shareware Version. To Decode all DTCs
    P3105 - 35-10 - Please Register/Activate - Intermittent
    18080 - Shareware Version. To Decode all DTCs
    P1672 - 35-10 - Please Register/Activate - Intermittent
    18044 - Powertrain Data Bus: Missing Message from Airbag Controller
    P1636 - 35-00 - -
    17932 - Shareware Version. To Decode all DTCs
    P1524 - 35-10 - Please Register/Activate - Intermittent

    1) N18 again, fine
    2) N239 again, fine
    3) Engine cooling fan, fine
    4) Airbag controller, fine
    5) Fuel pump relay, fine

    Cool, electrical issues sorted. I guess I'd better investigate the measuring blocks next and see how it's looking when running
    Last edited by fuus; 02-03-2019 at 01:25 PM.

  4. #664
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    Running it yesterday initially yesterday the injectors were showing that massive disparity (-2 and +2mg/str right next to each other).

    Once the motor had warmed up a bit these were the figures. 40C for fuel seems a bit high to me?
    few mins in.JPG

    Think I might make a post over on TDI Club and see what they think
    Last edited by fuus; 03-03-2019 at 09:08 AM.

  5. #665
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    May 2014
    Location
    Shropshire
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    So I suppose I'd better properly explain my problems to you all before jumping in the deep end and looking for answers and going round chasing my tail:
    My issues split into two main categories:
    1) The misfire on start
    2) The oil leak

    Full fat explanations:
    1) Ever since I got it running my Caddy has been rough when starting cold even when ambient is at 20C or so. This poor starting issue persisted after I sorted out the glowplugs. This sounds like a cylinder is missing and lots of white smoke is released which smells strongly of diesel.
    I believe this could be a sticking or lazy injector as when it's cold two cylinder's fuel injection values are quite large variations (See pic.1). When the engine warms up these values calm down and even out, as shown in pic.2.
    I'm not really sure if there's anything else I can do, aside from pull the injectors and get them bench tested? I'm lucky in that United Diesel who refurb PD injectors are 5 minutes down the road, but it'd be a pretty pricey way to go so ideally like to avoid.

    PIC 1
    injectors.JPG
    PIC 2
    few mins in.JPG

    2) The oil leak. As you can see from my previous photo (pic.3) there was a significant oil leak down the drivers side of the engine, causing the whole wheel arch to become covered in oil. I initially thought this was the product of oil from the crankcase breather system dripping out of the bottom of the intake where it attaches to the turbo. This in turn was dropping onto the driveshaft and being flung around the bay. Under further inspection however, this does not seem to be the case. Oil seems to be leaking out somewhere inside the cam covers Could be the crank seal, it's a bit early to tell from my teardown. (pic. 4/ 5). Bonus points for anyone who can spot what I broke in pic.4....
    PIC 3
    Attachment 33520
    PIC 4
    20190303_160536.jpg
    PIC 5
    20190303_160542.jpg

  6. #666
    Join Date
    Dec 2009
    Location
    Inverness
    Posts
    633
    Poor starting could be an injector seal. Its leaking the fuel into the cylinder and draining the gallery in the head.
    Injector loom harness can cause issues as well.
    I suspect from the figures that 1 injector is stuck nearly open . My pd150 bora had an issue where the idle was terrible and the readings were 0.14 0.12 2.99 0.14 Swapping out the no 3 injector cured the problem. one of the seals has a flat spot ,When it was cold overnight the seal would shrink and the fuel drain into the cylinder,
    Last edited by ScotClayShooter; 03-03-2019 at 08:52 PM.

  7. #667
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    Quote Originally Posted by ScotClayShooter View Post
    Poor starting could be an injector seal. Its leaking the fuel into the cylinder and draining the gallery in the head.
    Injector loom harness can cause issues as well.
    I suspect from the figures that 1 injector is stuck nearly open . My pd150 bora had an issue where the idle was terrible and the readings were 0.14 0.12 2.99 0.14 Swapping out the no 3 injector cured the problem. one of the seals has a flat spot ,When it was cold overnight the seal would shrink and the fuel drain into the cylinder,
    I perhaps didn't explain it properly (or maybe I did), but let me explain it in more detail and you can try and do yes or no. It starts on the button, no long cranking process to get fuel into the head, sweet as a nut. The issue is just once it runs it's rough and smokey. I guess this leans me more towards an injector not opening when it should?

  8. #668
    Join Date
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    Location
    Inverness
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    The bora would idle a bit rough , The midrange was a bit juddery, But it would take full throttle and top 130mph.....
    It never flagged up any faults. I changed just about everything before the injector. £65 and the bolts fixed it

  9. #669
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    Popped the rocker cover. Cam seems okay, bit worn but nothing drastic. but honestly bit clueless what I'm looking for...

    Got on the phone with diesel guru Taggy and he agrees with you Scot, likely an injector leaking. I think next step is to compression test to rule out the basics and go from there

    20190306_202943.jpg20190306_203001.jpg

  10. #670
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    So with the cam ruled out the next step was to sort this oil leak before testing compression (it was driving me nuts)

    So even with the engine not running there is oil running out of here, is this anything to worry about or just a natural thing?

    WhatsApp Image 2019-03-17 at 11.51.30.jpg

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