Chat Scrap it or make it a project? Update: a project it is!

Riba said:
Managed to pull the engine fault codes, not sure what to make of it:

4 Faults Found:

17055 - Cylinder 1 Glow Plug Circuit (Q10)
P0671 - 35-10 - Electrical Fault - Intermittent
17056 - Cylinder 2 Glow Plug Circuit (Q11)
P0672 - 35-10 - Electrical Fault - Intermittent
17057 - Cylinder 3 Glow Plug Circuit (Q12)
P0673 - 35-10 - Electrical Fault - Intermittent
19559 - Motor for Intake Manifold Flap (V157)
P3103 - 35-10 - Malfunction - Intermittent

Is it possible that all the glow plugs are faulty or should I look elsewhere?
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Evening,

It would be very unfortunate to have all 3 glow plug or their looms with intermittent faults. Confirm that these faults remain present or come straight back after clearing them…

If so then I’d add another earth from the engine to the chassis with a jump lead or similar and then rescan to see if they finally clear. If they do then it’s a no doubt a bad/weak earth, which should be easily rectified.

This is just a guess and I usually stay clear of these type of questions as it’s not my better area of knowledge.

Kind regards,

Tom
 
2work said:
Evening,

It would be very unfortunate to have all 3 glow plug or their looms with intermittent faults. Confirm that these faults remain present or come straight back after clearing them…

If so then I’d add another earth from the engine to the chassis with a jump lead or similar and then rescan to see if they finally clear. If they do then it’s a no doubt a bad/weak earth, which should be easily rectified.

This is just a guess and I usually stay clear of these type of questions as it’s not my better area of knowledge.

Kind regards,

Tom
Click to expand...

Good point, I already removed the battery, gave it a full charge and cleared the faults after reinstalling it but they came back. I'll check for the proper grounding, doubt that the glow plugs/connections are the root cause.
 
Wouldn't have thought the glow plugs would be monitored to the point they cause a eml to be lit be happy to be corrected! On my 2005 1.9tdi galaxy (basically a vw other than the immobiliser) I have taken the glow plug loom off started the car without any issue (was a moderate outside temperature) and no faults at all shown or recorded but also the EGR isn't monitored and the eml is just the glow plug lamp flashing so maybe it's different.
Guessing your issue here is the motorised intake valve which I presume replaced the basic ASV found on earlier cars?
 
A test light or multimeter fitted between a glow plug wiring plug and earth will tell you if the glow plugs have power
 
Reading through the service manuals, it mentions 4 different engine codes (ATL, AMF, ANY, BHC). Is there an easy way to find out which one I got?
 
Riba said:
Reading through the service manuals, it mentions 4 different engine codes (ATL, AMF, ANY, BHC). Is there an easy way to find out which one I got?
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Look through your rear rims to see if you have rear disc brakes, only the 90bhp ATL had it of the diesels.
 
That's easy then, it does have rear disc brakes. Good to know as ATL has a specific procedure for glow plug fault diagnostic. If I am reading this correctly glow plug failure will trigger EML on ATL engine. Thanks!
 

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Riba said:
Reading through the service manuals, it mentions 4 different engine codes (ATL, AMF, ANY, BHC). Is there an easy way to find out which one I got?
Click to expand...
As I said in post 5 - it's a 90 at a first glance - there is a red i in the Tdi badge visible not used on the other 1.4tdi models (unless someone has been swapping badges around). This is the ATL engine code. As stated above, rear disc brakes on the 90hp diesel model are a visible technical identifier only present on the 1.6FSi otherwise (unless someone has been swapping axles around). If you're looking in the engine bay, the boost pressure sensor is plumbed into a port drilled into the side of the L-shaped metal pipe running back from intercooler to intake in the 90 ; in the 75s the sensor is plumbed into the intercooler body and the L-shaped pipe has no port in it as well as being slightly longer at the end nearest the bulkhead. If you've got eyes on stalks that can go down the back of the engine there is also a differently-shaped interface between the turbocharger and the exhaust compared to the 75s owing to the different type of turbocharger.

AMF and BHC are 75hp 1.4tdi early and late (late 2002 switchover)

ANY is 1.2tdi 3L model (continental europe only ; many physical and structural differences).

The engine model code identifier is present printed on the build sticker in the battery compartment and reproduced in the rear of the service manual, as well as on the bar-coded sticker on the casing that covers the belts at the left-hand end of the engine (as viewed when you take the bonnet - and engine soundproofing cover in diesel models - off).

Note - the relevant LHD intercooler pipes with 8Z1 part codes are very different in appearance, although the equivalent return pipe has a similar sensor port in it. RHD are 8Z2 part codes. The photograph is a right-hand-drive 75hp intercooler return pipe with flow from right hand end to left hand end as it is positioned. On the rhd ATL/90 schematic below, the intake manifold end is shorter, and there is a port for the pressure sensor between the bracket and the right hand end (as pictured).

1704113562500.png


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Thank you for the quick crash course!

Without knowing the service history (apart that nothing major has been done during the three year ownership of the previous owner), am I right to assume I need to start planning for the DMF replacement? There is a slight noise present when pressing the clutch when cold, but apart from that seems to be fine.
 
Anecdotally that is the main failing of the 90. I don't have a 90, but the impression I've had ever since coming here having bought an A2 is that common consensus with 90s is that it is a case of "not if, but when" as mileages and ages increase, so that you need to plan for it in the same way as for any known maintenance job.

see here for more-educated discussion -

ATL clutch & DMF replacement parts

As discussed and highlighted by @dj_efk here... https://a2oc.net/community/index.php?threads/parts-mods-accessories.20902/page-26 I ordered this clutch kit (£320 delivered - best price I know of)...
a2oc.net
 
I think the DMF wear has a lot to do with how the 90,s are driven. Ethel is coming up to 20 years old this year and at 96,000 miles the clutch is still good. I do drive her sedately though and have a new clutch kit tucked away just in case.
 
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Incase you need to rebuild your glow plug loom.

About 1 metre downstream of the glow plug connectors, (if you were able to see through the protective plastic trunking surrounding the loom) the 3 glow plug wires are connected to one larger wire via a metal crimp and become 1 thicker wire traveling through the bulkhead into the car.
Note, this is on a TDI 75 it may or may not be the same for a 90.


I may have missed it in your post.
Could you post the battery voltage with ignition on. With no ingnition and the car at idle ?
Great work.
 
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I'm pretty sure glow plug failure will not trigger a fault on the dash. It never has for any of my tdi90's. As such it is very possible that all three glow plugs are broken if they have not been checked or replaced over the years. So I would simply check the resistance in situ from the end of the plug (after having carefully pulled off the "solid" rubber connectors) to the cylinder head or any other earth. Be careful pulling off the rubber glow plug connector as it will be fragile.

The asv will be causing the engine light. Very common. The gears inside get stripped. It's possible to get new gear sets for them on ebay and repair yourself. I would stick with plastic gears as although the brass ones that are available seem like a good idea, in my experience the don't quite fit.

The battery compartment in the boot is plastic.

If that is all that is wrong with it then you have landed a real bargain.

Happy new year.
 
Thanks, I've already done my homework with the ASV so that should be a straightforward job. I will check the glow plugs as soon as the perpetual rain stops along with their relay and as you said none of this is a big deal to sort out.
As a preventive maintenance I'll look into changing the belts, water pump and fuel filter at least....possibly a turbo rebuild.
 
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I don't know about the ATL engine, but in my T5 1.9TDI BRR, faulty glow plugs caused EML and "emissions - service" note on display... I think ATL uses 5 Volt glow plugs as well as BRR, so it may have the same functions 🤔
 
Leaky door sorted out in a separate thread, but now getting ready to remove and inspect the intake flap that's throwing an error. Checked the service manual and searched the forum but did not find the guide to remove the intake flap. It is seems pretty straightforward, I am only unsure how the rubber intake hose is attached to flap body. Do I just pull it out?

Thanks!
 
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