Custom Tune/Chip

[97B4TDi]

I got a mild injector upgrade last year with some Bosio nozzles and I was curious who I should talk to about getting a simple "tune."

Also the car sputs and stutters for 30 seconds to a minute in the morning. Along with lots of smoke. Should I get this adjusted before the tune or should the "tune" fix this problem?

Thanks

 

[Yblocker]

You might check (or have someone check) the injection timing with VCDS. Get that dialed and do your basic air filter maintenance first. Get the car running well then get your chip. The chip tune will not solve problems caused by other basic maintenance issues. Any chance the poor running started with the nozzle change?

 

[97B4TDi]

It did and it hasn't been adjusted properly since. The closest person I trust checking it out is Jason down in madison, but its a bear to get in his busy schedule.

 

[Yblocker]

Yeah, sounds like IQ or timing or both. New copper sealing washers under the injectors, balancing the pop pressures etc, are also all little details that make the nozzle upgrade go smoothly too.

Do you have the desire to do the IQ check and timing adjustment work yourself? It would mean an investment in the Ross Tech cable or equivalent and a set of basic tools. Might be worth it if you plan to keep the car and the guy who works on it is hard to schedule.

 

[97B4TDi]

The nozzles were balanced and pop tested by drivebywire and I'm assuming a regular tdi mechanic will know to replace the copper washers as well. Or at least hope so.

I've thought about it and have interest in it but am fearful of doing something harmful or destructive.

 

[Yblocker]

a

Pretty cold out your way this time of year. Can you discern a poor running pattern based on ambient temperature? Does the glow plug cycle seem to be working?

I can understand the trepidation on your part, but I think it's like most things in life though, you don't know what you can do until you try. You can't hurt a thing by checking the IQ and the timing with VCDS, so don't worry about that. There is plenty of information and support on this board to help with minor adjustments like the hammer mod for the IQ, as well as timing adjustments. Plus after you successfully get the car running well, you can have the satisfaction of having done it yourself without the dude in Madison!

 

[TonyJetta]

As others have suggested, check timing, injector balance, and scan for codes.

Hard start / smoke from a cold (<50F engine) usually is GP and/or timing related.

Did the coolant temp sensor get plugged in? Is it in the correct sensor? Most VW connectors are uniquely keyed, but do have duplicates scattered throughout the car.

Tony

 

[Yblocker]

Course, that's not to say anything about ol' Justin in Madison. Sounds like he's busy!

 

[97B4TDi]

Got in today and everything was spot on! Just starting rough because I overlooked a the burnt out "fuse-able link" in the relay near the firewall under the hood.

Ahhh...the simple things. Thanks for all the help. Up next? Some exhaust work and a mild rocketchip tune!!

 

[TonyJetta]

Got in today and everything was spot on! Just starting rough because I overlooked a the burnt out "fuse-able link" in the relay near the firewall under the hood.

I think that is the Coolant Glow Plug controller. I don't think they come on until <0F, IIRC.

Look over the B4 Glow Plug Relay thread fro GP troubleshooting.

Tony

 

[97B4TDi]

Yeah replacing the link under the hood did nothing to change my starting(cold) issues...

 

[TonyJetta]

Ok...follow the GP Troubleshooting thread I posted above.

Post back any questions, other issues, or troubleshooting help you need.

Tony

 

[97B4TDi]

Im trying to troubleshoot and I think my next step before replacing the relay under the dash would be replacing the "jumper" and I was curious how I make one.

 

[97B4TDi]

Replaced relay 180 as well as checked the white 80 amp fuse and the voltage at the glow plug harness

I am getting 12v at each plug. LOST

I dont know if this may be related but What would blow the linkable fuse in the coolant glow plug relay consistently?

 

[TonyJetta]

Now, check each individual GP. They should be <~1 ohm. If you get any >10ohm, they are certainly bad.

Tony

 

[97B4TDi]

I checked each plug and they were all between .9 and 1.0 ohm. In regards to your question; Yes, I soldered in a new glow plug harness about a year ago.

This morning I still had a misfire feel to the throttle for a couple minutes of driving.

Maybe clean my grounds?

One thing I didn't mention is I got bigger injectors last year. The timing and IQ is spot on, but I was curious if simply the extra fueling before the engine is fully warmed up may cause a misfire like symptom?

 

[TonyJetta]

When you checked the timing, did you select the right engine? I'm asking because it is easy to select the wrong engine. I've done it, then caught myself when the timing didn't look right.

Tony

 

[97B4TDi]

Jason's TDI repair in Madison checked the timing so i'm assuming he chose the correct engine.

 

[TonyJetta]

Then we need to check the coolant temp on the dash, against fuel temp (IP), against coolant temp the ECU reads. You will need VCDS.

The other option here, is to replace the CTS. Fortunately, it's <$20, so it's not an expensive to shotgun.

Tony

 

[97B4TDi]

Just replaced the coolant temp sensor & thermostat two months ago along with the plugs.

Could the fuel temperature sensor possibly be faulty?

 

[rdkern]

Do you have access to VCDS? If so, you can see what the CTS is telling the ecu.

You could also re-check the timing. If you didn't adjust the iq with the new nozzles, you may need to reduce the fueling a tad.

Cleaning the grounds never hurts, but probably isn't part of your issue.

 

[97B4TDi]

Yeah i have a buddy in town that has it or there is a gentleman in oshkosh with it as well; im just unfamiliar how to use it. When i get access to it what should I be watchful for?

Jason JUST checked the IQ and timing a week ago. Spot on.

 

[TonyJetta]

When i get access to it what should I be watchful for?.

Look at Fuel Temp, Coolant Temp, and dashboard coolant temp. On a cold engine they should be quite close, +/-5F or so. Generally when the CTS fail, it gives a very disparate number from the other temps.

Tony

 

[97B4TDi]

Alright thanks! I'll be checking it tomorrow and keep yah updated!

THANK YOU GUYS!

 

[97B4TDi]

I checked the measuring blocks today and the coolant temp sensor read 26-28 degrees Celsius, fuel temp was 6.3 degrees Celsius and the ambient air temp is around 14.4 Degrees Celsius.

EDIT: The engine was last operated 5 hours before checking these items.

Could the broken "fuse-able link" on the firewall in the engine bay throw the sensor off?

 

[TonyJetta]

I checked the measuring blocks today and the coolant temp sensor read 26-28 degrees Celsius, fuel temp was 6.3 degrees Celsius and the ambient air temp is around 14.4 Degrees Celsius.

Looks like your CTS is in the early stages of failure. Replace the CTS! Reading 12-22C high, is WAY more than enough for the ECU to not turn on the glow plugs when they are needed.

EDIT: The engine was last operated 5 hours before checking these items.

That should be plenty of time for the temps to cool down. If you want, you can repeat the test, with a longer cold soak time. Or, check with the engine hot. Hot, I would expect the fuel temp and coolant temp to be kinda close, within 5C or so.

Could the broken "fuse-able link" on the firewall in the engine bay throw the sensor off?

Nope! That fuseable link is for the Coolant Glow Plug Controller (pic below)...NOT the Combustion Chamber Glow Plug, that nearly everyone talks about.


[Tony

 

[97B4TDi]

Alright I'll replace the Coolant Temp Sensor and go from there!

 

[97B4TDi]

Now I'm confused. I stopped at the auto parts store and they said "the one for the computer or the one for the dash?"

I thought they were the same thing?

 

[TonyJetta]

Which sensor do you have? This blue one? Or the Black/Yellow unit?

My '96 uses the Black/Yellow which is both sensors wired independently. IIRC, the blue is a single sensor.

Tony

 

[97B4TDi]

Which sensor do you have? This blue one? Or the Black/Yellow unit?

My '96 uses the Black/Yellow which is both sensors wired independently. IIRC, the blue is a single sensor.

Tony

I have the Black?Yellow sensor, but that doesnt clear up my confusion. Is there another coolant temp. sensor I am overlooking?