Stuttering, coughing at 2500 rpm

Hello all,

I have a 2006 Jetta TDI 1.9L BRM, standard transmission. From day one of owning it (new with 537 miles) the car would stutter, or cough as my wife says, when driving around 2500 rpm, in all gears but 5th. It does not happen while in cruise control that I can recall. It would happen once in 4-6 months at first, but gradually started to happen more frequently. Now it happens several times in a 35 mile drive (my standard commute). At the same time my fuel economy has fallen from 45+ mpg to 30mpg.

I have replaced and upgraded the cam shaft, replaced the maf, replaced the oil pump, and done all scheduled maintenance. My timing belt recently went early and caused me to rebuild the head. Ouch. While the engine was apart I checked all the components and could not find anything wrong. After putting it all back together the stuttering/coughing problem remains. The turbo boost and acceleration is not smooth, but sudden, and after a delay.

My mechanic has suggested that the throttle position sensor on the gas pedal may be the culprit. I am new to the TDIclub, and hoping that someone out there may have some insight or suggestions. I am about ready to scrap the car, as I do not think I could find a buyer with all these issues, but would sincerely love to get it back to it's former self.

Thanks

I'd say you need to search the zip tie mod. I had the same on my car and performing that mod fixed it. I used tie wire instead of a zip tie, since it doesn't melt.

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zip tie mod

Thanks Mozambiquer. I am trying to find some info on the zip tie mod. Not much luck so far but I'll keep trying!

idk8750 said:

Thanks Mozambiquer. I am trying to find some info on the zip tie mod. Not much luck so far but I'll keep trying!

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Zip tie mod how to?


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That's the thread when I was in the same predicament. I pulled a vacuum on the actuator and then used a loop of mechanics tie wire (nothing special, just sounds more professional to call it mechanics tie wire)
I looped the wire around the actuator rod and and the bracket above it.

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