Lumpy T6 - Triggers Broom! Misfire & Vibration under 1500rpm.

DXX - The van is going to a specialist on the south coast on the 14th of August (Earliest they could get me in), he seams confident that its a rod, (as he has done a few before) but is going to do a strip down and go from there, nobody near me has enough knowledge on these engines for me to trust them, I'm 4.5k in so far and its still not right.

I have ordered one this morning just to try it. In the grand scheme of things its a mere drop in the ocean compared to what I have spent so far, if a revised £60 part fixes it its worth a try I guess.

Adam
 
Wednesday,26,July,2023,14392522064
VCDS -- Windows Based VAGVAS Emulator Running on Windows 11 x64
VCDS Version 23.3.1.0 (x64) HEX-V2 CB 0.4631.4
Data version 20230421 DS346.2
www.Ross-Tech.com


VIN WV1ZZZ7HZKX002183 License Plate


Chassis Type 7H-VN75 (7E0)
Scan 01 02 03 04 08 09 10 13 15 17 19 25 5F 61 69 0B

VIN WV1ZZZ7HZKX002183 Mileage 95190km-59148miles

01-Engine -- Status OK 0000
02-Auto Trans -- Status OK 0000
03-ABS Brakes -- Status OK 0000
04-Steering Angle -- Status OK 0000
08-Auto HVAC -- Status OK 0000
09-Cent. Elect. -- Status Malfunction 0010
10-ParkSteer Assist -- Status OK 0000
13-Auto Dist. Reg -- Status OK 0000
15-Airbags -- Status OK 0000
17-Instruments -- Status OK 0000
19-CAN Gateway -- Status OK 0000
25-Immobilizer -- Status OK 0000
5F-Information Electr. -- Status OK 0000
61-Battery Regul. -- Status Malfunction 0010
69-Trailer -- Status OK 0000
-------------------------------------------------------------------------------
Address 01 Engine (2D2D2-CXHA) Labels. 04L-907-309-V2.clb
Part No SW 04L 906 056 KG HW 04L 907 445
Component R4 2.0l TDI H02 3771
Revision 23002001
Coding 00254014432401090000
Shop # WSC 35110 790 50316
ASAM Dataset EV_ECM20TDI03004L906056KG 004004
ROD EV_ECM20TDI03004L906056KE_004.rod
VCID 7CA1E713266E04EA533-8028
VINID 9E606AAAA1D8A9BA000020480CDD0BF2E2

2 Faults Found
24836 - Torque Difference Cylinder 2
P1005 00 [096] - Limit Value Exceeded
Intermittent - Not Confirmed - Tested Since Memory Clear

31103 - SCR NOx Catalyst Bank 1
P20EE 00 [096] - Efficiency too Low
Intermittent - Not Confirmed - Tested Since Memory Clear

Readiness NA


This came up 10 days ago, so I swapped Injector 1 & 2 around and its come back again.

so its cylinder 2 that's giving the faults... has to be a rod/valve on cylinder 2.

Adam
 
Blind_Spark said:
Wednesday,26,July,2023,14392522064
VCDS -- Windows Based VAGVAS Emulator Running on Windows 11 x64
VCDS Version 23.3.1.0 (x64) HEX-V2 CB 0.4631.4
Data version 20230421 DS346.2
www.Ross-Tech.com


VIN WV1ZZZ7HZKX002183 License Plate


Chassis Type 7H-VN75 (7E0)
Scan 01 02 03 04 08 09 10 13 15 17 19 25 5F 61 69 0B

VIN WV1ZZZ7HZKX002183 Mileage 95190km-59148miles

01-Engine -- Status OK 0000
02-Auto Trans -- Status OK 0000
03-ABS Brakes -- Status OK 0000
04-Steering Angle -- Status OK 0000
08-Auto HVAC -- Status OK 0000
09-Cent. Elect. -- Status Malfunction 0010
10-ParkSteer Assist -- Status OK 0000
13-Auto Dist. Reg -- Status OK 0000
15-Airbags -- Status OK 0000
17-Instruments -- Status OK 0000
19-CAN Gateway -- Status OK 0000
25-Immobilizer -- Status OK 0000
5F-Information Electr. -- Status OK 0000
61-Battery Regul. -- Status Malfunction 0010
69-Trailer -- Status OK 0000
-------------------------------------------------------------------------------
Address 01 Engine (2D2D2-CXHA) Labels. 04L-907-309-V2.clb
Part No SW 04L 906 056 KG HW 04L 907 445
Component R4 2.0l TDI H02 3771
Revision 23002001
Coding 00254014432401090000
Shop # WSC 35110 790 50316
ASAM Dataset EV_ECM20TDI03004L906056KG 004004
ROD EV_ECM20TDI03004L906056KE_004.rod
VCID 7CA1E713266E04EA533-8028
VINID 9E606AAAA1D8A9BA000020480CDD0BF2E2

2 Faults Found
24836 - Torque Difference Cylinder 2
P1005 00 [096] - Limit Value Exceeded
Intermittent - Not Confirmed - Tested Since Memory Clear

31103 - SCR NOx Catalyst Bank 1
P20EE 00 [096] - Efficiency too Low
Intermittent - Not Confirmed - Tested Since Memory Clear

Readiness NA


This came up 10 days ago, so I swapped Injector 1 & 2 around and its come back again.

so its cylinder 2 that's giving the faults... has to be a rod/valve on cylinder 2.

Adam
Click to expand...
It does seem to be pointing to that. I can't see what else it would be as you have done just about everything you can. What's weird is the garage claiming the compression tests OK. A bent rod would give a lower pressure on that cylinder.

I've seen a sticking/broken piston ring that caused problems until the engine heated up but was easier to find as it was also causing visible blue smoke from the exhaust.

I think you have no choice but to trust the garage. Will be interesting to see their findings. Good luck.
 
New G247 sensor fitted, old one on the left new one on the right, idle seams smoother when hot, although not holding much hope but it's worth a try.

The test will be tomorrow Am on a cold start.

20230727_175952.jpg
 
Update..
Dropped off to Specialist on Saturday, they have just called....

Compression test... All cylinders below 20 Bar - Cylinder 2 at 16Bar, It should be considerably higher on a van that has only done 60k

Tear down starts tomorrow :(
 
Wow. So it must have ingested enough coolant while running to hydro-lock. I've only ever seen 1 engine survive that. I've got 31 years working with large marine engines and only the QM2 managed a similar fate and bent some rods without actually ejecting them out of the side of the block on one of its engines. Sounds like you have found a gem of a workshop who really knows their stuff. At least there's a logical explanation on the problem.
 
How are you getting on with this? Would interesting to understand the root cause and repair costs. Seems the EGR must have had a fair leak which ended up in the cylinders. Seems there's issues with most EGRs across the engine range, all leading to engine damage if not addressed?
 
Blind_Spark said:
Update.
Rods 2 & 4 visibly bent.

Bores are ok, so going to put pistons in acid to clean and check for cracks.

The plan is a new set of rods, bearings, rings and a hone.
Click to expand...
I’ve no idea how robust a T6 crankshaft is but is there a plan to check the crankshaft deflections in place?
 
Well.....
I'm still waiting and running out of patience, bear in mind this is my work van and I can't really work without it, I had to wait a month for it to be booked in because they like to allow time to do the job whilst its here...

From what I understand, they have all the parts now, They were waiting for a piston that was delivered last Wednesday.

When I rang last Thursday I was promised a call back.... nothing

Called back at 5PM to ask and got a passive aggressive - I can't work anymore hours it will be ready when its ready, not really helpful when you are trying to run a business.

Even if they said another 2 weeks, I could hire a van!
 
Nam600 said:
How are you getting on with this? Would interesting to understand the root cause and repair costs. Seems the EGR must have had a fair leak which ended up in the cylinders. Seems there's issues with most EGRs across the engine range, all leading to engine damage if not addressed?
Click to expand...

Long drive to Kent Circa 100 miles and low coolant light came on (Never come on before)
Topped up Came home, Low coolant light
Diagnosed as Charge cooler changed
another 100 miles coolant light on
EGR Changed - Coolant loss gone.

So around 3 Max-Min cycles caused it, I recon its 250ml from min to max.

I guess if it starts loosing coolant stop driving it immediately!
 
A lesson to all, if you are loosing coolant don’t just keep topping it up.
Keep us updated with the outcome.
 
Picked it up tonight, circa 250 mile trip home.

New Piston no2
X4 new rods
X4 New rings
New main and rod bearings
New head gasket & Head Bolts etc
Oil and filter etc.

Bill was just over 4k, but that includes Ecutune Map at £449.

EGR is now mapped out and blocked off too!
 
DXX said:
Another possibility is that one of the connecting rods is very slightly bent as a result of the leaking charge air cooler dumping water into a cylinder causing hydraulic lock.
It maybe so slight that the engine runs but with a slight deviation in compression ratio, again causing issues with fuel ignition.
As you know that all injectors are easily removable it would be a simple procedure to compare measurements to the piston crowns at TDC with a depth gauge.
Click to expand...
 
Blind_Spark said:
Picked it up tonight, circa 250 mile trip home.

New Piston no2
X4 new rods
X4 New rings
New main and rod bearings
New head gasket & Head Bolts etc
Oil and filter etc.

Bill was just over 4k, but that includes Ecutune Map at £449.

EGR is now mapped out and blocked off too!
Click to expand...
Was that 4K on top of the 4.5K you have already spent .

I'm currently experiencing the lumpy start, changed camshaft and coolant temp sensors as indicated by carista but all faults back within a day.

Mine is T6 18 plate with 79k on the clock.

I've a feeling it will be an expensive fix despite the van driving ok, bar the occasional coolant temp sweep up to 130° even when the oil temp is 60°.

Did this finally resolve your problem @Blind_Spark
 
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