[Roberts189]

Hi after some help please?

A few weeks ago my van (2005 1.9 102ps 137,000m) suddenly went really slow as if there was no boost, had a look and found that a boost pipe had popped off the near side of the intercooler due to the little nipple breaking. I replaced the pipe and although it was better it was still down on power and sounds a bit tappety (like an old ka/transit) I had it plugged in but there was no fault? It is also using more fuel than usual??

Then today I went on a long journey and was in a rush back so did push it on the motorway a bit then when I stopped the whole van was shaking as though an engine mount or something has gone but the revs aren't hunting?? U can really feel it through the floor especially in the pedals and engine noise is worse?

I suspect that these could be 2 separate issues as the revs are steady? Any help on either would be greatly appreciated, I fear the bill I could end up with! Every search I do suggests serious issues such a dmf, turbo and camshafts..... NO!!!

 

[JefeDeMaquinas]

My initial guess would be DMF
What milage has U`t van then?

 

[Roberts189]

It is just short of 138,000 mate and as far as I am aware the dmf has never been done but it seems to have developed this judder instantly where I would expect the dmf the be one that gradually gets worse? I could be completely wrong there?

 

[nelly]

injector gone down?
running on 3 ?

 

[Roberts189]

Another possibility but would that not make it idle funny as the revs are steady on idle? Is there away of checking so i could rule it out?

 

[glynch]

Camshaft lobe wear can cause rough idle as the cam operates the injectors.
It's well documented on the tdi forum that cam wear is a major downside of pump duse motors.
Couple that with poor oil choice and infrequent servicing.....
If it sounds like a transit then this could be the cause

 

[Roberts189]

I know replacing the cams wouldnt be cheap but has anyone got a rough idea on price? And do u think that could be the cause of both issues?

 

[glynch]

Mines rough on cold idle for a few seconds so mine could well be injector issue.
Removal and resell/refits about £250 plus I'm going to get mine tested/cleaned/calibrated.
If duff I think there around £200 each.
You can get a complete 1.9 cam kit for around £150 but not sure if their any good??
To replace cam and followers etc is about 2-3 hrs labour I believe bud

 

[Roberts189]

Ok mate niceone. I'm going to have a good poke around it today to see if i can figure out whats going on. I'll keep u posted but if anyone has any ideas in what i should be looking for in the meantime that could be usefull

Thanks

 

[glynch]

Worth googling PD cam etc
Lots of info on the vw tdi forum including photos etc.
Bear in mind that the 8valve pd heads are basically all very similar if not the same.
Obviously slight variations on injector sizes etc due to kw output (horsepower).

 

[nelly]

just a thought about the injector issue maybe?
I had a 115 gttdi golf and an injector went down whilst driving and I tell you what I thought a wheel was coming off,it was terrible ,shaking like mad
iirc the motor ran okish on tickover
a new injector sorted it instantly ,but at the time I think it was best part of 500 quid just for the part
lets hope its not that then
just my thoughts mind, probably wrong AGAIN

 

[Roberts189]

Thanks Any suggestions welcome! I started it this morning and the shaking is no where near as bad and its not noticable when driving. I disconnected the battery for an hour to see if it cleared limp mode and checked all the boost pipes for leaks but couldnt find any yet its still really down on power! It feels like an air leak as it kinda judders when it should be boosting? Yet there is boost because all the pipes go hard when revving the engine?

Would the cam effect power? And is there any way of checking if the injectors are ok? I wish it would just throw the management light up and tell me what the issue is! Going to book it in the garage this week and let them sort it, hopefully without charging me a fortune!

If any can recommend somewhere in birmingham that would be helpful?

 

[surfsteve]

I had that, it was the DMF that had excessive movement, I thought it was injector porblems too but it was not . This was caused by the failing gearbox main shaft bearings. It was solved immediately.

I found this out after not getting the gearbox serviced at it seemed fine at 1mm play on shaft laterally, but in fact when under load it was out of tolerance and causing the clutch plate to shear off at the inner section to outer friction plate section and causing damage to the DMF .

I paid this by removing and installing myself

new DMF, clutch drive plate, cover and thrust bearing £400- LUK
gearbox looked at and bearings changed - £700 _ local gearbox specialist

Good luck