Misfire in 2006 Jetta 1.9L TDI

   #1  

TFSI

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Hello friends,

I have a TDI with engine misfire in cylinder three.I opened valve cover to inspect connections to all injectors-they look tight! Not sure what else to look for.
I have taken some readings, not sure what they mean. The injection quantity deviation in logs shows negative, not sure if this is normal or thats incorrect. Help will be appreciated!
Thanks for reading.

Code:
Monday,05,September,2016,18:02:40:46890
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 7 x64
VCDS Version: 16.8.0.3 (x64)
Data version: 20160803 DS255
[url]www.Ross-Tech.com[/url]


VIN:    License Plate: JAY JETTA TDI



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                Address 01: Engine       Labels: 038-906-016-BEW.lbl
Control Module Part Number: 03G 906 016 AB    HW: 028 101 223 8
  Component and/or Version: R4 1,9L EDC G000SG  7550
           Software Coding: 0050071
            Work Shop Code: WSC 00066 000 00000
                      VCID: 63CE6695A2E2925ADD-8036
8 Faults Found:

005659 - Glowplug for Cylinder 2 (Q11) 
               P161B - 000 - Open Circuit - Intermittent
             Freeze Frame:
                    Fault Status: 00100000
                    Fault Priority: 0
                    Fault Frequency: 1
                    Reset counter: 255
                    Mileage: 378245 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 14:58:03

             Freeze Frame:
                    RPM: 252 /min
                    Speed: 0.0 km/h
                    Load: 0.0 %
                    Voltage: 10.41 V
                    Bin. Bits: 00001100
                    Temperature: 22.5°C
                    Bin. Bits: 01110000

005660 - Glowplug for Cylinder 3 (Q12) 
               P161C - 000 - Open Circuit - Intermittent
             Freeze Frame:
                    Fault Status: 00100000
                    Fault Priority: 0
                    Fault Frequency: 1
                    Reset counter: 255
                    Mileage: 378245 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 14:58:03

             Freeze Frame:
                    RPM: 252 /min
                    Speed: 0.0 km/h
                    Load: 0.0 %
                    Voltage: 10.41 V
                    Bin. Bits: 00001100
                    Temperature: 22.5°C
                    Bin. Bits: 01110000

005661 - Glowplug for Cylinder 4 (Q13) 
               P161D - 000 - Open Circuit - Intermittent
             Freeze Frame:
                    Fault Status: 00100000
                    Fault Priority: 0
                    Fault Frequency: 1
                    Reset counter: 255
                    Mileage: 378245 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 14:58:03

             Freeze Frame:
                    RPM: 252 /min
                    Speed: 0.0 km/h
                    Load: 0.0 %
                    Voltage: 10.41 V
                    Bin. Bits: 00001100
                    Temperature: 22.5°C
                    Bin. Bits: 01110000

000771 - Cylinder 3 
               P0303 - 000 - Misfire Detected - Intermittent
             Freeze Frame:
                    Fault Status: 00100000
                    Fault Priority: 0
                    Fault Frequency: 5
                    Reset counter: 255
                    Mileage: 378245 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 16:21:34

             Freeze Frame:
                    RPM: 819 /min
                    Speed: 0.0 km/h
                    Load: 0.0 %
                    Voltage: 14.14 V
                    Inj. Quantity: -2.99 mg/str
                    Temperature: 26.1°C
                    (no units): 0.0

000305 - Oxygen (Lambda) Sensor B1 S1 
               P0131 - 000 - Signal too Low - Intermittent
             Freeze Frame:
                    Fault Status: 00100000
                    Fault Priority: 0
                    Fault Frequency: 1
                    Reset counter: 255
                    Mileage: 378245 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 16:22:09

             Freeze Frame:
                    RPM: 777 /min
                    Speed: 0.0 km/h
                    Load: 0.0 %
                    Mass Air / Rev.: 430.0 mg/str
                    (no units): 0.20
                    (no units): 0.0
                    Bin. Bits: 10001001

008759 - Oxygen (Lambda) Sensor B1 S1 
               P2237 - 000 - Pump Current Open Circuit - Intermittent
             Freeze Frame:
                    Fault Status: 00100000
                    Fault Priority: 0
                    Fault Frequency: 1
                    Reset counter: 255
                    Mileage: 378245 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 16:23:39

             Freeze Frame:
                    RPM: 819 /min
                    Speed: 0.0 km/h
                    Load: 0.0 %
                    Mass Air / Rev.: 420.0 mg/str
                    (no units): 0.20
                    (no units): 8.0
                    Bin. Bits: 10001001

000768 - Random/Multiple Cylinder Misfire Detected 
               P0300 - 000 - 
             Freeze Frame:
                    Fault Status: 01100000
                    Fault Priority: 0
                    Fault Frequency: 5
                    Reset counter: 255
                    Mileage: 378245 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 16:25:47

             Freeze Frame:
                    RPM: 819 /min
                    Speed: 0.0 km/h
                    Load: 0.0 %
                    Voltage: 14.14 V
                    Bin. Bits: 00001000
                    Temperature: 33.3°C
                    Bin. Bits: 01010000

000770 - Cylinder 2 
               P0302 - 000 - Misfire Detected - Intermittent
             Freeze Frame:
                    Fault Status: 00100000
                    Fault Priority: 0
                    Fault Frequency: 1
                    Reset counter: 255
                    Mileage: 378245 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 06:12:48

             Freeze Frame:
                    RPM: 840 /min
                    Speed: 0.0 km/h
                    Load: 0.0 %
                    Voltage: 14.36 V
                    Inj. Quantity: 2.96 mg/str
                    Temperature: 24.3°C
                    (no units): 0.0


Readiness: 1 4 0 0 1
Code:
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Address 01: DTCs cleared
--------------------------------------------------------------------------------
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                Address 01: Engine  (03G 906 016 AB)

18:04:27 Group 013: Idle Stabilization (Injection Quantity Deviation)
  -3.01 mg/str  Injection Quantity Deviation Cyl. 1
  2.99 mg/str  Injection Quantity Deviation Cyl. 2
  -3.01 mg/str  Injection Quantity Deviation Cyl. 3
  2.99 mg/str  Injection Quantity Deviation Cyl. 4

--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


                Address 01: Engine  (03G 906 016 AB)

18:04:28 Group 013: Idle Stabilization (Injection Quantity Deviation)
  -3.01 mg/str  Injection Quantity Deviation Cyl. 1
  2.99 mg/str  Injection Quantity Deviation Cyl. 2
  -3.01 mg/str  Injection Quantity Deviation Cyl. 3
  2.99 mg/str  Injection Quantity Deviation Cyl. 4

--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


                Address 01: Engine  (03G 906 016 AB)

18:04:29 Group 013: Idle Stabilization (Injection Quantity Deviation)
  -3.01 mg/str  Injection Quantity Deviation Cyl. 1
  2.99 mg/str  Injection Quantity Deviation Cyl. 2
  -3.01 mg/str  Injection Quantity Deviation Cyl. 3
  2.99 mg/str  Injection Quantity Deviation Cyl. 4

--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


                Address 01: Engine  (03G 906 016 AB)

18:04:30 Group 013: Idle Stabilization (Injection Quantity Deviation)
  -3.01 mg/str  Injection Quantity Deviation Cyl. 1
  2.99 mg/str  Injection Quantity Deviation Cyl. 2
  -3.01 mg/str  Injection Quantity Deviation Cyl. 3
  2.99 mg/str  Injection Quantity Deviation Cyl. 4

--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


                Address 01: Engine  (03G 906 016 AB)

18:04:32 Group 013: Idle Stabilization (Injection Quantity Deviation)
  -3.01 mg/str  Injection Quantity Deviation Cyl. 1
  2.99 mg/str  Injection Quantity Deviation Cyl. 2
  -3.01 mg/str  Injection Quantity Deviation Cyl. 3
  2.99 mg/str  Injection Quantity Deviation Cyl. 4

--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


                Address 01: Engine  (03G 906 016 AB)

18:04:48 Group 012: Glow Plugs
  11111111  Glow Status 
  0.00 s  Pre-Glow Period 
  14.36 V  Supply Voltage (Terminal 30)
  53.1°C  Coolant Temperature (G62)

--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


                Address 01: Engine  (03G 906 016 AB)

18:04:50 Group 012: Glow Plugs
  11111111  Glow Status 
  0.00 s  Pre-Glow Period 
  14.44 V  Supply Voltage (Terminal 30)
  54.0°C  Coolant Temperature (G62)

--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


                Address 01: Engine  (03G 906 016 AB)

18:05:00 Group 010: Charge Pressure Control
  365.0 mg/str  Mass Air Flow (actual)
  1009.8 mbar  Atmospheric Pressure
  989.4 mbar  Boost Pressure (actual)
  0.0 %  Accel. Pedal Pos. Sensor 1 (G79)

--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


                Address 01: Engine  (03G 906 016 AB)

18:05:02 Group 010: Charge Pressure Control
  340.0 mg/str  Mass Air Flow (actual)
  1009.8 mbar  Atmospheric Pressure
  989.4 mbar  Boost Pressure (actual)
  0.0 %  Accel. Pedal Pos. Sensor 1 (G79)
 
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   #2  

MartinsX

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Your injector corrections (deviations) are critical!
What happened with this engine before? Some major repairs? Toothed belt replacement? What mileage it has?
Do the compression test. Check camshaft for excessive wear. Take Your injectors to diesel equipment test facility. I don't know situation in US, but in Europe almost every diesel equipment workshop can do CR tests but only some can do PD. Ask them before bringing Your injectors to them.
 
   #3  

TFSI

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Hi MartinsX,

You mean all all injectors deviate?car was bought used, according to the previous owner, complete engine was replaced.car has over 210,000 miles.
 
   #4  

Uwe

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There are very few diesel passenger cars in the US, so there are not many places that can test injectors properly.

As for a negative deviation on the injection quantity, that would be OK, if they were within the +/- 2.8 mg/str limits. But they are ALL outside those limits. Given that 2 cylinders are at +3.0 and two are at -3.0, I wonder if the problem the injectors?

I think I would start with a compression test.

-Uwe-
 
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MartinsX

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Was this car just bought and already have misfires or You drive this car for some time and then faults appeared? If engine was replaced with another used one, You can't know mileage of engine itself. 210 000 miles are more than 300 000 km. At 300 000 km a lot of 1,9 PD TDI engines are in critical condition...

FYI: "Injector deviation" is very, very theoretical measurement calculated by ECU. In simplified it could be explained: ECU increases or decreases fuel amount injected to each cylinder to achieve smooth running at idle. Bad injector is only one of factors causing correction figures to go outside acceptable range (typically +/- 2,5 mg/str). Bad compression, crankshaft/camshaft misstiming, badly worn camshaft, leaking injector sealing rings are the most common another ones for PD engines.
 
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TFSI

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Car was bought with same issue.seller said he changed the engine but replaced old injectors with used ones from another car but same part number. I will do the compression tests and engine timing recheck and post results here.
 
   #7  

MartinsX

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There are very few diesel passenger cars in the US, so there are not many places that can test injectors properly.
-Uwe-
In that case it will be really hard to get PD injectors tested properly in US. As we know, VAG is almost the only one using PD injectors in passenger cars. All others jumped from classic VE pumps to CR. Some Mitsubishi models have PD engines, but those are just modified VW engines. 2,0 TDI PD with code BSY
For testing PD injector, completely different test equipment is used. It's not reasonable for any workshop to purchase expensive equipment and use it couple times a year...
 
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MartinsX

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Do the seller had the same problems with old engine and/or with old set of injectors?
Are there some differences how engine works cold and hot? More/less vibrations, harder/easier to start etc.?
 
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TFSI

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No he didnt have same problem with old engine. Engine starts right away cold or warm..oh but in the U.S we dont have cold weather yet, been super warm down here Maryland DC Virgina areas.
 
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MartinsX

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1) What is in Your fuel tank? Are You sure it's a pure diesel? I have seen similar injector deviations when someone missfueled his diesel car with gasoline. Pure gasoline will not start at all but mix up to 50:50 can cause something like this.
2) Is the injector replacement done correctly? New sealing sets, new fixing bolts tightened to specification, adjusted correctly? . Replacing PD injectors is another one tricky thing.
 
   #11  

Jack@European_Parts

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I think if used FOD injectors were installed, how about checking the PD lash of the gap everyone negates to do for the tappets?

I bet it wasn't done and FYI the pintails wear too.

In addition to hogged out lifters or warn cam lobes.
 
   #12  

ivagp

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since u have the cover off did you inspect the cam. not the intake or exhaust lobes but the ones that drive the injectors
 
   #14  

TFSI

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MartinX,

Thanks, this is a very useful idea.I will look into all these points and post back results soon. You seem well experienced with these engines.
 
   #15  

MartinsX

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MartinX,

Thanks, this is a very useful idea.I will look into all these points and post back results soon. You seem well experienced with these engines.
TDI's are very popular in Europe. But almost all second hand TDI cars have great mileages. Because diesel is cheaper than gas and people planning to drive a lot are buying TDI's. And selling them to Eastern Europe afterwords.
 
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