Chugging

[srafferty]

My car - 2001 1.9 tdi has many issues.

 

One I would like any helpful advice on in this thread is chugging.

 

I am not sure wheather it is related to the other issues so I will list them.

 

First of all my mechanic bypassed the ERG some time back to stop the car chugging. He did this by inserting a small bolt quite securely into the small hose which comes out of the horizontal pipe on the top. I recently undid this and connected the pipe again and the ghugging has returned. I would prefer to fix the cause of the problem rather than just bunging the hose again. the car has a slightly spluttery idle and chuggs under gentle acceleration. On the odd occasion when the turbo does decide to work, it does not chugg.

 

Other issues which may or may not be relatedare as follows.

Iwould like to deal with them in separate threads later.

 

 

• I have a limp mode issue showing P1556 code.
  
• Black Smoke.
  
• Parking sensor fault.
  
• Bulb warning light on instrument cluster which extinguishes when I first press the brake pedal. ( I seem to remember this being the case from new but didn't pay much attention)
  
• Poor fuel consumption.
  

 

Any thoughts gratefully appreciated.

[gregers]

just googled limp home mode and found this,

http://wiki.ross-tech.com/index.php/17964/P1556/005462

bulb warning light is normal,usually stays on if it detects a problem i:e bulb blown.

parking sensor do a search on here a lot of info about these.

fuel consumption could be related to the other problems your having.

[srafferty]

Thanks Gregers I saw that one before. Any ideas why it runs smoother with ERG by-passed.

 

My mechanic really know these PD engines And he's stumped about the limp mode. I think I'll just have to replace stuff hose by hose, valve by valve etc. Its only done 68K and hasn't really run properly for 1/2 of that.

 

ERG by-pass?

[gregers]

has he mentioned the maf,these seem to cause no end of trouble? when they fail.do a search for them on here and see if the syptoms are similar.

[srafferty]

Swaped my MAF with a friends workinng Sharan - No different. I'm on my third by the way. :angry2:

[seatkid]

Any ideas why it runs smoother with ERG by-passed.

EGR - Exhaust Gas Recirculation

 

It should only open at medium engine loads/speeds - its used to reduce the combustion temperature and limit NOx

 

It sounds as if the EGR valve is stuck open - either clean it or replace it - this is probably the cause of the poor consumption and black smoke.

[srafferty]

Thank you SeatKid

 

Any idea how much one costs - curiosity I'll get a new one regardless. :angry2:

 

I'll let you know how I fare.

[me myself and I]

Thank you SeatKid

 

Any idea how much one costs - curiosity I'll get a new one regardless. :angry2:

 

I'll let you know how I fare.

 

 

I know from a differnent car (pajero) that taking of and cleaning the EGR valve can only help the engine.It gets clogged up with a lot of black gunk and basically hinder rather then help an engine and in many cases on the pajero people have put a piece of metal over the egr with very little if any ill-effect on the engine.But as I said it was on a pajero.Might do no harm to remove your and soak it in diesel for a few hours.remember if you are getting black smoke its not burning fuel right (fuel pump....timing slightly out?) then egr may be feeding this black smoke back into your engine hence causing it to stutter/act strange and as Seatkid says it certainly wont help your mpg.

HTH

[Willie Krashitt]

Agreeing with others re sticking EGR valve. If the EGR valve is sticking open, then there won't be enough exhaust energy to spin the turbo up properly, meaning low boost pressure. Not enough air going in = black smoke and poor performance/fuel consumption.

 

As has been said, clean out the valve and cooler, it is a LOT cheaper to do, and these older design vacuum operated valves are cleanable. (VW want around

[srafferty]

Guys, I'm very much obliged for your help. It all makes sence.

 

Sorry for calling EGR erg :blink:

 

When you say cooler what are you referring to?

I'm a rookie - Sorry

[Willie Krashitt]

Exhaust gas can get extremely hot, and with a heavy car on the ECE emissions drive cycle NOx emissions can be a big problem. As I mentioned above, adding exhaust gas (EGR) into the inlet charge lowers the combustion temperature and reduces NOx emissions. However, due to the vehicle weight, significantly more gas needs to be recirculated than would be the case for the same engine in say, a Golf. This in turn makes the intake charge very hot, losing efficiency.

To resolve this, a cooler/heat exchanger is added to the EGR pipework, and this is placed just before the EGR valve.

See item 5 in the attached picture.

 

George.

[srafferty]

Update

 

EGR removed cleaned - about 3mm of gunk removed. Managed to break the lower flange with third bolt hole. I think it it was fractured before I got to it as it broke without much movement. Anyway, re-assembled (with only 2 bolts). Couldn't wait to drive my "new" car. Result? - No different. Woops forgot to connect the hose which works the valve. Reconnected - really excited - result? Better, but not much. Tick over better but still chugs under light load, and fuel consumption still poor. :blink: All in all 10% improvement at best.

[srafferty]

It occurs to me that there may be no vacuum in the pipe which closes the valve. Anyone any thoughts?

[gio]

It occurs to me that there may be no vacuum in the pipe which closes the valve. Anyone any thoughts?

The valve should be closed anyway, the vacuum should suck the valve open at light throttle so if the vacuum was not working and after you cleaned the Egr valve it was in the closed position[normal] then the vacuum not working would not be an issue.

 

Indeed if the egr valve is faulty, then clean it up leave it in the closed position and disconnect the vacuum pipe anyway, save your money and spend it else where.

 

It will not effect your vehicles performance or passing of the MOT.

 

Your vehicle, is it still smoking black smoke? it might be worth getting you entire exhaust system including the cat cleaned our. Air line and soft rubber mallet as if its been smoking black smoke the build up in your exhaust system could lead to some of the proplems you are encountering, indeed it could lead to other problems if not cleaned out...

Edited April 18, 2009 by gio

[srafferty]

The hose I was refering to is the one at the back of the EGR valve which opens the throat. When I appiied a vacuum to the pipe at the top which is I presume the one you mean there was a small movement inside.

 

I may be confusing people here as I' not that clear on the hose names etc.

 

PS I am very grateful for everyone's help by the way. If I can get to the bottom of my woes I'll get my mechanic to sort it out properly, but I can't afford to pay him for experimenting!

 

At that point I'll take your good advise about the exhaust.

Edited April 18, 2009 by srafferty

[srafferty]

Does anyone have a schematic diagram of the 1.9 tdi

[gregers]

have a look on ebay for a tis disk,this is the technical information disk on the galaxy and other ford cars,but beaware of copyright etc etc :blink: :D

[srafferty]

Thanks again Gregers, I have TIS. It doesn't have quite what I'm after.

[srafferty]

Update-

 

New MAF genuine VW - just for the sake of it - No different.

 

New EGR - chugging has stopped & black smoke is reduced. I suppose that indicates it's doing its' job better and recirculating more exhaust.

 

I still have poor performance below about 2200 rpm and 26mpg.

 

New MAP sensor due THursday - fingers crossed.

 

I am assuming since I have turbo above about 2200 that the turbo unit is not at falt