Problematic A3 2004 2.0 TDi BKD Engine

a3evotg

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Won this beautiful black A3 SE TDi off eBay, complete with R32 alloys and all the toys inside, heated seats, cruise control etc.... It was advertised as having a blown turbo.

Now I have owned a BKD engined car before and upon collecting it, the turbo was fine, it has the usual whine these engines have, but when giving it some it was flat as a pancake. I then went on to find 3 boost hoses just not even held in, one going to the ASV, and the other 2 underneath, from passenger side of intercooler leading up the ASV, at both joins there had also gone, so i drilled and screwed all three. It now pulls like a train.

I am just left with 3 issues.

One - There is an engine mount knackered, i cannot workout which, but its rocking back and forth like mad and its chewed up all the sound deadening on the back of the bulkhead at the back of the engine

Two - It won't idle properly when warm, its fine when its cold, but when warm it all over the place, sounds like its misfiring

Three - It doesnt like cruising or being held at between 2000 and 2500 revs when driving, if you try to cruise at these revs it just starts misfiring and lurching forward/kangarooing

So I have full Vagcom on my laptop. I did a full scan and found ZERO fault codes on the engine.

I then did research and to date I have done the following.

Removed cam cover, unplugged each injector one by one and started it after unplugging each, this only made it run ten times worse and it threw a fault code for each Injector i unplugged, plugged them back, in, put it back together, cleared the codes, took it for a run, rescanned, no codes, and still the same problems mentioned above in 2 + 3

I then removed the fuel filter, to check for a bad filter, and for water or oil in the filter housing, suggesting maybe the injector seals had gone, and the fuel was fine and free of contaminants

I then bunged up the vac hose to the EGR and blanked it off using a plate. No difference whether its bunged up/blocked off or not.

Its a bit hesistant starting, it sort of like makes that sound when batterys flat where it cant quite turn the engine over then it dies? but once its made that first hesistation it fires into life?

There is no smoke from the exhaust, when cold or warm, it does chuck grey smoke out but that was only when the boost hoses were loose, doesnt seem to do that now.

Problems just seem to begin once the car is up to temperature, the dodgy idle and the not liking cruising at 2000 - 2500 revs

People are saying injector wiring loom, the turbos coked up, or the timings out.

Its only done 108,000 miles on a 04 plate, and it had a cambelt at a non dealership garage at 103,000 miles.

Can someone suggest anything else I can check ? it rattles when i turn it off, which points to the ASV, but then my MK5 did this and it threw a code the ASV was knackered, but this hasnt?

Can anyone tell me how using full vagcom I can check the timing, check what the injectors are doing, and boost levels ?

Many thanks
 
Ive ran some logs on vcds and the injector values seem to be up and down? EGR seems to be okay but not according to VCDS. Also when i ran the output tests once i got to V157 inlet manifold flap and tested it the car engine stalls?

The log

Friday,06,March,2015,20:58:00:33490
VCDS -- Windows Based VAG/VAS Emulator
VCDS Version: 12.12.3.0 (x64)
Data version: 20140905


VIN: VSSZZZ1MZ4R008425 License Plate: XX04XXX



--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


Address 01: Engine (03G 906 016 G)

20:57:44 Group 013: Idle Stabilization (Injection Quantity Deviation)
-1.51 mg/str Injection Quantity Deviation Cyl. 1
1.39 mg/str Injection Quantity Deviation Cyl. 2
0.71 mg/str Injection Quantity Deviation Cyl. 3
-0.59 mg/str Injection Quantity Deviation Cyl. 4

--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


Address 01: Engine (03G 906 016 G)

20:58:36 Group 017: Readiness Code (EOBD)
00000000 CARB Mode 01 DATA A
01100110 CARB Mode 01 DATA B
10000000 CARB Mode 01 DATA C
10000000 CARB Mode 01 DATA D

--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


Address 01: Engine (03G 906 016 G)

20:58:44 Group 018: Injector Status
0.0 Injector Status Cylinder 1
0.0 Injector Status Cylinder 2
0.0 Injector Status Cylinder 3
0.0 Injector Status Cylinder 4

--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


Address 01: Engine (03G 906 016 G)

20:59:03 Group 023: Injector Switch Time Deviation
-26.0 Switch Time Deviat. Cylinder 1
-41.0 Switch Time Deviat. Cylinder 2
-34.0 Switch Time Deviat. Cylinder 3
-46.0 Switch Time Deviat. Cylinder 4

Any ideas ?
 
Thanks, what could be causing this? Faulty injectors, faulty loom, or timing? How do i check the timing? thanks
 
I changed the injector loom in my one when it was giving me the same misfire like symptoms. This seemed to cure it for a while but, the problem came back eventually. The injectors were all out and one replaced when the new head went on it.
I'm afraid to say, that the tick over problem, despite having about 2 grand thrown at it, was never satisfactorily cured.
I used to hear many a 2.0 TDI suffer in the same way when my one was in the garage.
:think:
 
I've had rough idle, rpms going up and down on idle (car sounded like it is misfiring), took the injectors to Bosch service and 600 Euros after, my car worked better than ever.

But your problem is probably the timing due to no huge offsets in injection quantity.
 
It had a timing belt 5000 miles ago. Could they have knocked the timing out?
 
Does anyone know the best values for the timing ? I believe its somewhere between -0.25 and +0.25 at least/most?
 
Im having the same issue in late 2004 early 2005. Car is going in on tuesday to see whats up. Would be interested to see if you figure out what the issue is. i dont want the lads coming back saying they cant find anything. cause as you mentioned nothing shows up on the codes. one of my mechanics reckons its the fuel pump they all give issues. Just sounds like a fuel issue. but the strangest one ever cause its only when the engine gets hot the issues kick in. and car starts shaking violently when any acceleration is applied otherwise perfect cold. hope you make progress. i can get back to ya if the lads figure out anything see if that might help
 
My rough idle is also when its warm. Mine doesnt shake violently but theres a noticeable judder at 2000-2500 revs.

Today im going to get the timing values from vagcom, and if they are out il get the local diesel specialist to time her up. I did reset the ECU in vagcom which kind of helped but then the problem came back after it had ran for a few minutes.
 
Ya I don't know why mine goes so bad sounds like a tractor until it's switched off. So there's no point in messing with the ecu if just went back to the issue
 
Torsion value when warm when it starts juddering is -2.0/-2.5, is this right?
 
Timing is now 0.0 spot on, loads better but still misfiring, theres a massive range of values in all injectors, dependent on whether its cold, warm, hot, etc, cant see all 4 injectors gone, so maybe loom?
 
Either the loom or the injectors themselves.

EDIT: If one is faulty, the rest will also go nuts trying to compensate in mg/stroke, so do not rule injector(s) out.
 
Ive ran some logs on vcds and the injector values seem to be up and down? EGR seems to be okay but not according to VCDS. Also when i ran the output tests once i got to V157 inlet manifold flap and tested it the car engine stalls?

The log

Friday,06,March,2015,20:58:00:33490
VCDS -- Windows Based VAG/VAS Emulator
VCDS Version: 12.12.3.0 (x64)
Data version: 20140905


VIN: VSSZZZ1MZ4R008425 License Plate: XX04XXX



--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


Address 01: Engine (03G 906 016 G)

20:57:44 Group 013: Idle Stabilization (Injection Quantity Deviation)
-1.51 mg/str Injection Quantity Deviation Cyl. 1
1.39 mg/str Injection Quantity Deviation Cyl. 2
0.71 mg/str Injection Quantity Deviation Cyl. 3
-0.59 mg/str Injection Quantity Deviation Cyl. 4

--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


Address 01: Engine (03G 906 016 G)

20:58:36 Group 017: Readiness Code (EOBD)
00000000 CARB Mode 01 DATA A
01100110 CARB Mode 01 DATA B
10000000 CARB Mode 01 DATA C
10000000 CARB Mode 01 DATA D

--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


Address 01: Engine (03G 906 016 G)

20:58:44 Group 018: Injector Status
0.0 Injector Status Cylinder 1
0.0 Injector Status Cylinder 2
0.0 Injector Status Cylinder 3
0.0 Injector Status Cylinder 4

--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


Address 01: Engine (03G 906 016 G)

20:59:03 Group 023: Injector Switch Time Deviation
-26.0 Switch Time Deviat. Cylinder 1
-41.0 Switch Time Deviat. Cylinder 2
-34.0 Switch Time Deviat. Cylinder 3
-46.0 Switch Time Deviat. Cylinder 4

Any ideas ?


Cam Shaft Sensor?
I had mines changed but it was throwing up errors on Vag Com...

also could be that timing belt was done incorrectly.
Get that checked out
 
No fault codes on vagcom mate, full vagcom too.

Looms coming out so i can bench test it, cheapest thing first, injectors are £60 a piece second hand on fleabay and even then id need to get them cleaned
 
No fault codes on vagcom mate, full vagcom too.

Looms coming out so i can bench test it, cheapest thing first, injectors are £60 a piece second hand on fleabay and even then id need to get them cleaned

Dont you need to code injectors to the car?

Loom could also be at fault...
 
Not sure, but even if so its no biggy with full vagcom i have
 
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I had my warm start issue and rough idling mapped out when I got the car remapped. the remappers (retch) knew of the issue and they fixed it.
 
Car went in today said he couldnt really find anything. But pointed out that he recons its the loom wiring as when its getting hot its becoming frail and causing the issues. your changing yours? hope theres an update if it works at least that wouldnt be too much of an expensive job to replace
 
Timing is now 0.0 spot on, loads better but still misfiring, theres a massive range of values in all injectors, dependent on whether its cold, warm, hot, etc, cant see all 4 injectors gone, so maybe loom?

0.0 means that the front cam is bang on

it doesn't mean the rear cam is bang on and this has to be done manualy by pinning the bottom crack and adjusting the top rear pulley.
also injectors might need to be set at the same time .

also you need a warm start map which most good mappers know how to do ( r tech )
 
Car went in today said he couldnt really find anything. But pointed out that he recons its the loom wiring as when its getting hot its becoming frail and causing the issues. your changing yours? hope theres an update if it works at least that wouldnt be too much of an expensive job to replace
Well that's a cheap fix then ...£85 for a loom plus labour unless you DIY. Sposed to be straight forwRd enough
 
Well that's a cheap fix then ...£85 for a loom plus labour unless you DIY. Sposed to be straight forwRd enough

The lad qouted me €330 to do the work. €100 for the cable and €230 for labour because its under the rocker cover . if it was an easy enough id nearly put it up and mess around myself save the labour but i dont know where to begin
 
The lad qouted me €330 to do the work. €100 for the cable and €230 for labour because its under the rocker cover . if it was an easy enough id nearly put it up and mess around myself save the labour but i dont know where to begin

Its an extremely simple job. Remove rocker cover (buy a new gasket for it at the same time) unplug the loom and throw a new 1 in.

SIMPLES
 
The lad qouted me €330 to do the work. €100 for the cable and €230 for labour because its under the rocker cover . if it was an easy enough id nearly put it up and mess around myself save the labour but i dont know where to begin

I only got charged £120.00 inc labour.
It's not a big job but 330 Euro is a bit pricey...!
:think:
 
fedup with it, only bought it as a project with a turbo issue, turbos fine, 3 pipes hanging off.fixed that, drives fine jus rough idle
 
Just said id update on this if it he's got the problem sorted after plenty of testing. main specialists couldn't figure out but went to a polish lad and he found the no.4 injector was gone. Car was running smoothly until another problem went. not sure if your still fixing it but just said id update