Bew_Hiss
Member
Hi all, I have 260,000 miles on my 1.9 TDI BEW bought it about 3 years ago (220,000 miles). When I first bought the car it ran great. We have had several problems along the way but here is our latest dilemma. About a year ago in the summer, the car would experience issues in the morning after sitting all night. The car cranks, fires right off then dies immediately, then you have to crank it for several cycles with smoke pouring out the back before it starts and runs, then it develops a misfire at idle. After that it will restart great for the rest of the day. We ended up replacing all 4 injectors with rebuilt ones with new seals. This seemed to fix the long cranking times (for about 6 months) and the smoke but did not fix the misfire. This misfire began in the summer and continued into winter, it is not present on start up but seems to develop after the engine is warm and goes away as the rpms rise. At cruising speeds and driving around it is un-noticeable but at idle it shakes the whole car. Now the long crank has come back and the misfire is still there. After about 6 months of long cranks, a cough, and then a weak sounding start (then drives OK enough to drive the car), now the car will crank but not start anymore without a shot of starting fluid in which case the car will start, run great on all 4 cylinders and over time progressively misfire worse and worse at idle until after a few minutes the car stalls. After the car dies it will crank fast and will not start again even with starter fluid until it sits overnight. Same thing tomorrow, car runs for about 5 mins every time. I am new to VCDS and have tried to use it to troubleshoot but it is proving difficult. An Engine 01 scan only shows a misfire on Cylinder 2, no other codes. I can see that there is RPMs on the TAC and in VCDS around 240 rpm at starting cranking speed after the car has died it will crank at 340 RPMs. After the car is first started Injector quantity deviation is stable within +- 1.00 , right before it stalls values are +-2.89. While cranking, injector values are 0.00. We originally thought the lift pump could have an issue after testing the flow from the fuel supply line and only getting 1.5 l/m vs the specified 3 l/m. we now get 2 l/m with the new lift pump. Not sure if the specified value is exact or if there could be something wrong with the new pump (doubt it) or if there could be a leak in the hard line running from the pump to the filter. We don't see or smell any fuel there. I would think this is still plenty of flow to supply the Tandem pump. I removed the glow plugs and there is no fuel being injected. I do not have clear fuel lines to tell if there is air in the system and if I understand correctly that both the lift pump and the tandem pump "Suck", then there would be no obvious leaks if there was a bad hose. Although the misfire has been apparent it seemed that the car had run so well when it first starts in the morning and even while driving that compression should be good. I had a look at the camshaft with the injectors still in and could not identify any obvious signs of wear but I have little experience when it comes to how bad is bad in that case. As I said the car seemed to run great the majority of the time until now and even if there was low compression, bad injectors, or worn cam I would still think the car would spit fuel and fire on at least one cylinder and start. Has anyone heard of a worn cam causing a no start condition? My next step is to replace the Crankshaft sensor as I have read many many threads on the various forums here (Thanks for all the great info everyone!!) and a handful of people state that there CRPS was faulty and not throwing any codes. I only have a code for misfire on Cylinder 2 and EGR Insufficient Flow because the pipe from the EGR cooler into the intake I have removed and installed block-off plates. Straight piped exhaust, no tune.
If anyone knows of anyway to log fuel pressure in VCDS on this engine it may help me determine if I am loosing fuel pressure for some reason. I can only seem to find "Charge pressure" as a %, not sure what that is. I don't seem to have alot of the options to monitor things like fuel rail pressure in VCDS, or the ability to test each injector. I have also heard of a TSB for the crank sensors on BEWs but someone said it only applied if you had a flash for a glow plug recall or something so not sure if that would apply to me or not so leaving it alone. If anyone has any input as too what I could check next or what the problem could be I would absolutely appreciate it as I have been unable to find anyone with a problem quite like this. I can add a full scan but I don't know how useful it would be.
This car has new:
Timing Belt etc (240,000)
Brake Booster (had a code for this)
Glow plug harness
Battery
Cam Sensor (had a code for this)
MAF sensor (had a code for this)
Coolant sensor (had a code for this)
More recently...
Fuel Filter and Lift Pump (last week-no code on this)
Tandem Pump(Bosch)- 15,000 miles ago (no code for this, guessed it might help when nothing else was, did this before the injectors)
Injectors-(rebuilt) - new Seals/bolts- 15,000 miles ago (this was the hail mary when still having the long crank weak start after we replaced the tandem pump, started without the long crank for about 6 months, we thought we had it fixed finally but no. Back to long crank weak start, and now....start only with ether and run a few minutes and stall.)
If anyone knows of anyway to log fuel pressure in VCDS on this engine it may help me determine if I am loosing fuel pressure for some reason. I can only seem to find "Charge pressure" as a %, not sure what that is. I don't seem to have alot of the options to monitor things like fuel rail pressure in VCDS, or the ability to test each injector. I have also heard of a TSB for the crank sensors on BEWs but someone said it only applied if you had a flash for a glow plug recall or something so not sure if that would apply to me or not so leaving it alone. If anyone has any input as too what I could check next or what the problem could be I would absolutely appreciate it as I have been unable to find anyone with a problem quite like this. I can add a full scan but I don't know how useful it would be.
This car has new:
Timing Belt etc (240,000)
Brake Booster (had a code for this)
Glow plug harness
Battery
Cam Sensor (had a code for this)
MAF sensor (had a code for this)
Coolant sensor (had a code for this)
More recently...
Fuel Filter and Lift Pump (last week-no code on this)
Tandem Pump(Bosch)- 15,000 miles ago (no code for this, guessed it might help when nothing else was, did this before the injectors)
Injectors-(rebuilt) - new Seals/bolts- 15,000 miles ago (this was the hail mary when still having the long crank weak start after we replaced the tandem pump, started without the long crank for about 6 months, we thought we had it fixed finally but no. Back to long crank weak start, and now....start only with ether and run a few minutes and stall.)
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