New tune, new problems

KidFromAkron

Active member
Joined
Sep 19, 2017
Location
ohio
TDI
2010 jetta
I installed the Malone tuning stage 2 on my 2010 jetta cr tdi six days ago. The car has seen regular scheduled maintenance by the dealer that I bought it from and has only 78,000 miles. While driving in normal stop and go traffic my glow plug light came on and started flashing. Car drove fine for the three miles till home then the check engine light came on just before killing the motor. The motor shuddered to a stop a little rough as well. Restarted and both lights still on. No limp mode as of yet. I called a local euro car specialist and he's going to scan it tomorrow morning. Anyone else see this with their new malone tune? Btw I'm new here and new to the upgrade world (at least on my dIesel).
 

travis45

Veteran Member
Joined
Dec 25, 2009
Location
Wisconsin
TDI
14 Sportwagen, 96 Passat TDI Sedan
I'm going to go out on a limb and say your tune had nothing to do with it and your hpfp just took a sh!t.

Open up your fuel filter and look for metal shavings in the bottom.

You need to scan with VCDS to see what codes come up.
 
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travis45

Veteran Member
Joined
Dec 25, 2009
Location
Wisconsin
TDI
14 Sportwagen, 96 Passat TDI Sedan
If it is the hpfp the preferred fix is to upgrade to a CP3 pump.
 
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KidFromAkron

Active member
Joined
Sep 19, 2017
Location
ohio
TDI
2010 jetta
I thought that maybe the sensors had a tendency to take a dump from the changes. Just spitballing. Guess I'll find out tomorrow. Thanks for the reply.
 

KidFromAkron

Active member
Joined
Sep 19, 2017
Location
ohio
TDI
2010 jetta
Scan showed intermittent TPS issue. By the time I took it to the shop the lights were out. they said bring it back if it starts again. There was no more rough stops when turning off the key but of course lights came back on and the rough stops are back. I'm assuming the problem is at the motor and not the throttle position sensor in the go pedal based on the rough stops. I'm almost due for my 80k mile service. I'll probably have it taken care of then. Any other suggestions?
 

KidFromAkron

Active member
Joined
Sep 19, 2017
Location
ohio
TDI
2010 jetta
So after taking some time to decide how to best spend my money I finally broke down and took my car to a non-dealer vw specialist to get a definitive diagnosis. I was torn initially on whether to just spend the $200 and get a VAG-COM and then just do the work myself (if I can) or go to a specialist and have them use their diagnostics and willingly pay the mark up.

Basically for $55 the shop diagnosed what I suspected: I need to replace the EGR valve air regulator flap.

I plan on doing the work myself because in my research I've found that this fix seems well within my wheel house seeing as how I know lefty looses righty tightey. In researching the actual part I found dap.com to have the oem part for $360 and ECS tuning had it for $357 which was from continental. A few key strokes later I found the same serial number continental part on amazon for $253 with free shipping. https://www.amazon.com/gp/product/B00O14NDK0/ref=oh_aui_detailpage_o00_s00?ie=UTF8&psc=1

With the money I save in part mark up and labor I plan on buying the ross tech VAG-COM to use later as I plan on getting at least another 200k miles out of my Jetta.

I'll post pics and updates of the work once the part comes in. Thanks again for following and helping with great input!
 

Nevada_TDI

Top Post Dawg
Joined
Aug 17, 2008
Location
Reno, sort of...
TDI
2001 Jetta TDI
Glad to hear you found a resolution, and as most here will say, "...If you own a VW you also need to own VCDS..." Or have a good relationship with someone that lives or works nearby where you live.
 
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oilhammer

Certified Volkswagen Nut & Vendor
Joined
Dec 11, 2001
Location
outside St Louis, MO
TDI
There are just too many to list....
I would ask the tuner what mods were done to the EGR systems and see if they have any insight.
 

740GLE

Top Post Dawg
Joined
Aug 19, 2009
Location
NH
TDI
2015 Passat SEL, 2017 Alltrack SE; BB 2010 Sedan Man; 2012 Passat,
So after taking some time to decide how to best spend my money I finally broke down and took my car to a non-dealer vw specialist to get a definitive diagnosis. I was torn initially on whether to just spend the $200 and get a VAG-COM and then just do the work myself (if I can) or go to a specialist and have them use their diagnostics and willingly pay the mark up.
Basically for $55 the shop diagnosed what I suspected: I need to replace the EGR valve air regulator flap.
I plan on doing the work myself because in my research I've found that this fix seems well within my wheel house seeing as how I know lefty looses righty tightey. In researching the actual part I found dap.com to have the oem part for $360 and ECS tuning had it for $357 which was from continental. A few key strokes later I found the same serial number continental part on amazon for $253 with free shipping. https://www.amazon.com/gp/product/B00O14NDK0/ref=oh_aui_detailpage_o00_s00?ie=UTF8&psc=1
With the money I save in part mark up and labor I plan on buying the ross tech VAG-COM to use later as I plan on getting at least another 200k miles out of my Jetta.
I'll post pics and updates of the work once the part comes in. Thanks again for following and helping with great input!

EGR exhaust flap?

I have one for sale if you're interested, shoot me a PM

http://forums.tdiclub.com/showthread.php?t=480015
 

740GLE

Top Post Dawg
Joined
Aug 19, 2009
Location
NH
TDI
2015 Passat SEL, 2017 Alltrack SE; BB 2010 Sedan Man; 2012 Passat,
Methinks the problem is not with one of the two EGR systems.

Agreeed, EGR exhaust flaps never threw a GP in my ride, it was always a CEL.
 

oilhammer

Certified Volkswagen Nut & Vendor
Joined
Dec 11, 2001
Location
outside St Louis, MO
TDI
There are just too many to list....
Since we have no DTC, we can really only guess what the issue is with the OP's car.

There are two completely separate EGR systems on that car. Most tuners will either greatly dial back or turn of both EGRs from functioning.

From what information was shared, my best guess is an issue with the intake manifold regulating flap (throttle valve), which is used primarily for high pressure EGR flow control and for smooth engine shut down.
 

KidFromAkron

Active member
Joined
Sep 19, 2017
Location
ohio
TDI
2010 jetta
I replaced the throttle body last night. It was easy in the grand scheme, only four bolts. Old throttle body was caked with soot but not as much as I'd expected. One day I'll figure out how to post pics. I think i'm going to clean it up and save it in case this happens again. Worth trying anyway.
Car instantly improved. Better throttle response and power, no more clunky stops of the motor at shut down. Check engine light is still on but no glow plug light. I ordered the VCDS from ross tech and it should be here in a couple days so I'll scan it and clear the CEL.
 

740GLE

Top Post Dawg
Joined
Aug 19, 2009
Location
NH
TDI
2015 Passat SEL, 2017 Alltrack SE; BB 2010 Sedan Man; 2012 Passat,
So it went from an EGR exhaust flap to a throttle body?
 

oilhammer

Certified Volkswagen Nut & Vendor
Joined
Dec 11, 2001
Location
outside St Louis, MO
TDI
There are just too many to list....
So it went from an EGR exhaust flap to a throttle body?

Well, that is the thing, the semantics of the low pressure EGR is such that the throttle body, intake regulating flap, throttle valve, EGR throttle valve, EGR flow control valve, and probably others I cannot remember, are all one in the same part. Different manufacturers (and different scan tools, for that matter) call the same part by different names. Even the Germans cannot agree. VAG, MB, and BMW all call the same part by a different name.
 

KidFromAkron

Active member
Joined
Sep 19, 2017
Location
ohio
TDI
2010 jetta
Got off shift yesterday morning and the CEL did not come on. Drove maybe 50 miles throughout the day and still no light. Car is running so much better! I accidentally left the part at work so I’m going to take pics tomorrow.
Eventually I plan on registering the car in a non-emissions testing county (somehow) and ditch the EGR completely as well as the DPF and probably the cats. I’m hoping Malone will rework my tune to take this into account without raking me over the coals. Sort of looking forward to my clutch wearing out so I can upgrade and go bigger on the power. I’ve really got my hands full now seeing as how I have a supercharged chevelle that’s nearly finished as well!
 

Owain@malonetuning

Associate Vendor , w/Business number
Joined
Jul 1, 2016
Location
Vancouver
TDI
PD jetta wagon
Don't think this has anything to do with the tune, feel free to shoot us an email though once you have VCDS and an idea of what's going on.
 

Ol'Rattler

Top Post Dawg
Joined
Jul 3, 2007
Location
PNA
TDI
2006 BRM Jetta
I thought that maybe the sensors had a tendency to take a dump from the changes. Just spitballing. Guess I'll find out tomorrow. Thanks for the reply.
Even with a tune, the sensors are still functioning exactly how they did before. They measure and report to the ECU what they measured.
 

KidFromAkron

Active member
Joined
Sep 19, 2017
Location
ohio
TDI
2010 jetta
Even with a tune, the sensors are still functioning exactly how they did before. They measure and report to the ECU what they measured.
And I figured they would, I just thought that maybe the tune might make the car run within ranges the sensors wouldn't like, hence causing the CEL and GPL to come on. Owain says no...
 

Ol'Rattler

Top Post Dawg
Joined
Jul 3, 2007
Location
PNA
TDI
2006 BRM Jetta
Any time you bump the power, it seems like the added power can find issues that were there all along, just not severe enough to cause a DTC (fault code) to be set yet. Or maybe the problem just plain old occurred, tune or not.
 

Owain@malonetuning

Associate Vendor , w/Business number
Joined
Jul 1, 2016
Location
Vancouver
TDI
PD jetta wagon
Exactly, if there's any imperfections in the car, they'll be amplified with tuning.

The strongest example of this in the VW world would probably be Mk4 1.8T tuning. The divert valves and N75s often start showing issues as soon as you throw more boost at them. Coil packs are another common one too, but they can fail if you look at them funny.
 
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