Hi,
2004 Mk6 2.0 TDI 100 PS: right hand drive, front wheel drive
I am trying to troubleshoot poor running (maybe is in limp mode) after replacing glow plugs and injectors, fixing a few leaks, coolant hose fixing, and renewing wrapping on wiring where it was frayed etc.
At moment engine starts but runs very roughly and lots of white smoke.
And lacks power: I doubt it would actually move.
It stops on its own after a few minutes.
On dash after it is running I get a flashing glow plug symbol, and also battery icon is on.
The strange thing is I have a generic ELM327 diagnostic Bluetooth interface to my android phone and am running EOBD Facile to see error codes etc.
It does not report any error codes now, although initially it did, until I fixed a faulty temperature sensor.
The glow plugs do work: I installed new ones with new wiring, and tested them hooked up to the circuit.
They all glow.
And when I start the engine I measure 38 amps to them with my fluke clamp meter, then it goes to zero after about 1 minute.
And icon starts to flash.
My injectors have been refurbished/cleaned (new nozzles) and tested by a diesel expert.
They function properly.
I have new fuel and air filters.
I did my best to bleed the air out of the fuel system: it starts easily, just doesn’t run very well.
I might replace the diesel hoses from the fuel filter to the pump (supply line and bleed off return) because the connectors at the fuel filter end were very hard to remove, and maybe maybe not sealing now.
Maybe.
Dunno if they ar bad.
I thought they were OK, but maybe are pulling in air???
My battery is new, and at each start I have 12.5-13.0 volts.
Dunno why charge icon goes on.
I don’t think it’s causing my problems.
It was ok before this.
As I said, I initially had a cylinder head temperature sensor Diagnostic Trouble Code (DTC).
So I replaced it.
I no longer have that Fault code.
I have not intentionally touched the timing: I did remove the timing chain cover to repair a leak, but didn’t touch the timing chain.
However I did I did rotate the engine by the crankshaft pulley a little bit backwards because I had dropped something into the cylinder 1 when cleaning out the glow plug holes. A Dremmel brush.
Sigh.
Was making sure the glow plug holes were clean....
But the engine never ran with it in, and I managed to fish it out with a magnet and using an endoscope.
It did not damage the cylinder.
But I did rotate the crankshaft back a bit to try to move the cylinder to a good position to fish it out.
But no more than maybe 1 turn backwards.
And then after that it was turned normal direction 1 turn.
Couldn’t rotate anymore either direction because the Dremmel brush was stopping the cylinder from moving its complete cycle.
But now I have the Dremmel brush out, and I reinstalled injectors and glow plugs.
I haven’t seen anything that suggests any internal damage: engine rotates manually fine.
Can you put the engine out of timing by rotating backwards a little bit??
I can check the timing if needed.
I have fuel: ½ tank.
The manuals suggest that perhaps these could be issues causing my problem:
T-MAP sensor
EGR valve (like what?? It is there and I don’t see any damage to it, how do you know??)
APP sensor
Fuel temp sensor (is in pump I believe, pump is pretty new)
Does my engine have a MAF sensor? (Air Flow Mass sensor?? I know Mk7 does, and a supplier selling sensors says the Mk6 does have one, but where is it??)
Any ideas on how to trouble shoot this please?
Other than not dropping Dremmel tools into cylinders...
Thanks for help