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Old January 29th, 2008, 09:33   #1
rc_y2kws6ta
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Join Date: Jan 2007
Location: Folsom, CA
Fuel Economy: 39.5 mixed, 43+ highway
Default Jetta stumbles-Out of ideas

I need help please!! I am out of ideas on what is wrong with my 02 Jetta A4 with 83k miles.
Any help would be greatly appreciated. It just seems to not adjust the pump timing correctly (or momentarily lose air) at low RPM’s and under load.

About three weeks ago my Jetta started to stumble and hesitate upon acceleration for a stand still. It would hit about 1800 RPMs and stumble. I would give it more peddle and it would then stumble a little more and finally accelerate with a dark sooty cloud.

I have isolated this behavior.
1) It runs perfectly fine after a cold start for about 30 minutes. After that, its starts to run bad.
2) The idle is fine.
3) The power is fine (once I get the RPMs up past the stumble point)
4) When its fully warmed up, the engine does not like to be at 1800 to 2500 RPMs. It will stumble and blow dark smoke.
5) Accelerating and accelerating under load seems to be the biggest problem.

I have checked the car over with a couple of TDI friends with a VagCom.
1) Check all the hoses and vacuum lines (Replaced suspect lines)
2) Check all the sensors (MAF, EGR, N75, needle lift etc.)
3) Checked the function of the actuator on the turbo.
4) Intake and EGR was cleaned 10k ago along with TB, and fuel filter.
5) Cleaned snow screen, air filter good.
6) Played with the IQ and pump timing. Moving them up seemed to help, after a day the problem came back.
7) Injection pump seems to be in great shape. (no leaks or bad noises)

My next steps are to…..clean the EGR again, replace the relay 109 and have the ECU scanned and sent to a tuner.
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2002 Black Jetta TDI 5-speed swap! Katzkin leather interior, SE 6-spoke BBS wheels, .184 Nozzles,tdituning.au
2000 Trans AM WS6 503 RWHP
2005 Honda Oddessy EXL
1998 Saturn SL2, 02 Kawasaki Ninja ZX9R
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Old January 29th, 2008, 09:35   #2
rc_y2kws6ta
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One other thing.....its NOT throwing any codes! (I wish it was at this point)
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2002 Black Jetta TDI 5-speed swap! Katzkin leather interior, SE 6-spoke BBS wheels, .184 Nozzles,tdituning.au
2000 Trans AM WS6 503 RWHP
2005 Honda Oddessy EXL
1998 Saturn SL2, 02 Kawasaki Ninja ZX9R
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Old January 29th, 2008, 15:43   #3
rc_y2kws6ta
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I will change the fuel filter again. Any other suggestions?
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2002 Black Jetta TDI 5-speed swap! Katzkin leather interior, SE 6-spoke BBS wheels, .184 Nozzles,tdituning.au
2000 Trans AM WS6 503 RWHP
2005 Honda Oddessy EXL
1998 Saturn SL2, 02 Kawasaki Ninja ZX9R
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Old January 29th, 2008, 18:19   #4
wolf1477
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Location: Tony,WI
TDI(s): 2000 Golf
Fuel Economy: 53+ Hwy, 35+ City
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Stupid question: When you replaced your fuel filter did you replace the o-rings?
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Old January 29th, 2008, 22:22   #5
rc_y2kws6ta
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Yep. I replaced the fuel filter 10k ago, with the supplied O-rings. I was careful with the pastic T as well.

I did check the boost with a VagCom (w/ a TDI friend). The boost was coming up fine.

I did find one fault code tonight and cleared it. Any insight on this fault code? A bad 109 relay?
17978/P1570 - Engine Start Blocked by Immobilizer

Possible Symptoms
  • Engine starting but stalling immediately
Possible Causes
  • Key(s) not matched
  • Instrument Cluster not matched
  • Engine Control Unit (ECU) not matched
  • Engine Control Unit (ECU) Power Supply faulty
Possible Solutions
  • Match Key(s)/Instrument Cluster/Engine Control Unit (ECU)
  • Check Engine Control Unit (ECU) Power Supply (Relay)
Special Notes
  • If no other immobilizer related fault codes are stored and the immobilizer related meas. blocks are fine except Engine Start not allowed, try cold-booting the car. Remove both battery cables from the battery. Short the battery cables together (away from the battery) for about 15 seconds. Reconnect the battery.
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2002 Black Jetta TDI 5-speed swap! Katzkin leather interior, SE 6-spoke BBS wheels, .184 Nozzles,tdituning.au
2000 Trans AM WS6 503 RWHP
2005 Honda Oddessy EXL
1998 Saturn SL2, 02 Kawasaki Ninja ZX9R
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Old January 30th, 2008, 17:55   #6
rc_y2kws6ta
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Really need help....
Intermitted Hesitation starting at 1800 RPMS accompanied by black smoke...

New sympton: The idle holds for the most part until I put it in drive or reverse...It will dip for a split second and recover....only does it two or three times
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2002 Black Jetta TDI 5-speed swap! Katzkin leather interior, SE 6-spoke BBS wheels, .184 Nozzles,tdituning.au
2000 Trans AM WS6 503 RWHP
2005 Honda Oddessy EXL
1998 Saturn SL2, 02 Kawasaki Ninja ZX9R
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Old January 30th, 2008, 18:16   #7
alphaseinor
 
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Fuel Economy: 35 in city floored, 48 on highway @75mph
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Turbo actuator is leaking... that's what mine was...

Could be the problem... I think someone was thinking about ice crystals or something...
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Old January 30th, 2008, 18:59   #8
rc_y2kws6ta
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Eck and I tested the actuator with a mityvac. It appear to move well and hold vacuum.
Was the the correct test?
Can I buy an actuator without the turbo?
Maybe it losing a fine movement, can it be cleaned?
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Old January 31st, 2008, 10:14   #9
rc_y2kws6ta
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I gave a the EGR a detailed cleaning and put it back on.
I noticed the turbo air intake pipe's spring clamp was about a 1/2 of an inch off, so I centered it back on. Are those really sensitive? I am wondering if it is a contributing factor to the hesitation.

I still need to drive it to see if its running better.
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Old January 31st, 2008, 19:09   #10
bob022004
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I'm running across the same problem myself. if i happen to figure something out i'll post up. just recently did the intake cleaning....the fuel filter isn't very old, i use bp diesel, brand new MAF sensor.
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Old February 1st, 2008, 08:34   #11
rc_y2kws6ta
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Thanks. I cleaned the ERG again and found a spring clamp on the turbo was slightly off. I lined it back up and throughouly checked all the hoses and piping. No Change.....

Visually, maintence schedule and on the vag-com my Jetta is in great running condition. I am going to switch out the injections with some new injectors, having a tuner verify the current programming, and upload a new tune. I am going to run somemore logs, just in case something changed or I missed something previously.

One good thing is...when your car puffs out some black smoke, nobody tail-gates you!!
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Old February 3rd, 2008, 20:43   #12
bob022004
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You're right about the smoke....funny stuff.

I'm thinking maybe the cat might be clogging. thinking of getting a test pipe when i get a chance. I'm out of town right now.
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Old February 4th, 2008, 09:29   #13
rc_y2kws6ta
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I THINK I FOUND THE PROBLEM! >>>MAF or MAF wiring
I figure I must have missed something and so I started testing everything over again.

We were driving it this weekend and it hit a dead spot where it wouldn't accelerate, started to stumble, then told off with a puff of dark smoke. During that time, the MAF reading would start low then jump high and continue to jump all over.
I unplugged the MAF and the car has not sumbled or hesitated since. It drives alot better with the MAF unplugged.

I will either order a new MAF or borrow a friends for testing.

I think test pipes are around $200. You might want to unbolt the exhaust after the turbo, hold it up with a hanger (if needed) and test drive. Unless of course you are just going to run it without a cat.
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Old February 4th, 2008, 09:38   #14
alphaseinor
 
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"test pipes" are about $20 + $40 to weld them in...
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Old February 4th, 2008, 09:42   #15
rc_y2kws6ta
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Are there bolt in test pipes? I exhaust shops in Cali won't replace a cat with a test pipe.
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