Information 1.6 FSI Problem

shery119

Member
Hello Everyone,

I have been browsing this amazing forum ever since i got my A2 and its a shame that my first post is about a problem, i have a 2003 1.6 FSI and its great when there's nothing wrong, the car is spluttering shaking and stalling when it is hot but when its cold there is a obvious misfire but it is not as bad and never dies when its cold , also the car slowly accelerates to 2800-3k revs and then violently shakes for a few seconds and stays at around the 3k mark and then continues the rest of the rev range with no loss of power! this is intermittent and happens regardless of the temperature. Local mechanic initially pointed to a new cat converter which didn't help although it did needed replacing as old one was disintegrated! next i changed the mass airflow sensor which again did not help, most recently i got a EGR blanking plate fitted but my mechanic had to drill another hole as it didnt line up with the EGR holes :confused: car seemed to run well after blanking the EGR albeit for 20 minutes then on leaving the A406 approaching a red light the car suddenly died and did not start again until cold !. Eventually got it back into the garage and plugged into a diagnostic machine and apparently it was not giving any fault codes so my mechanic reset the throttle body and called me to take it as he couldn't find the fault .

Does anyone know what could be causing this ? i am pretty sure the coil packs are doing their job as i have checked them by removing each one, is there anyone local to Ilford Essex that is willing to come have a look at the car? i can travel but the car becomes rough and eventually dies once it has warmed up so someone ever so local will be ideal.

Thanks for reading my essay lol and thanks in advance :)
 
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The car acting like it is must be generating fault codes. But unless your mechanic is useing vcds they may not be able to read them.

Some people with hand held code readers for example don't show any faults, but when vcds is plugged in then the codes come up.

You need to contact Sarge, his knowledge of A2s is second from none and has helped many a member.

http://www.a2oc.net/forum/member.php?4229-Sarge786

I don't know my way around London but I think he is relatively close to you.

Good luck I hope you get this sorted.

Cheers

David
 
Thank you riverlad, I will message sarge right away, plugged vagcom today and long behold 5 fault codes!
1- 17439 intake manifold tuning valve (n316) set point not reached - the guy doing my diagnostic said I need to clean out or replace my throttle body, Is this next to the maf sensor? Can't be that easy could it as I have searched this forum and people with the same code are opening up the inlet manifold,Is this the same as the throttle body?

2- 00600- potentiometer on positioning motor for temperature flap (g92) open or short to plus

3- 17912- Intake air system leak detected

The other codes were about a misfire at cylinder 1 probably because of oil buildup and a fuel pressure regulation/ control range exceeded.

The main aim is to sort out what the intake manifold tuning valve is and how I can rectify this ?
 
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This was the same as mine.... It is a terrible job and requires a lot of labour time to remove the tb

9 times out of 10 it cannot be fixed so a new intake is needed... Total part and labour cost £750 from specialist and God knows what from a dealer

If you are lucky the potentiometer can be replaced but this is rarely the case

Hope you are one of the lucky ones as these are great cars
 
Sorry to interfere in this thread

Can I ask other fsi owners if your car also has a symptom of nearly stalling, running very rough when oil cap ( at the top of engine ) is taken off?
 
thanks for your reply mjhamilton, so can i replace the throttle body i.e the motorised unit inbetween the MAF sensor and EGR Pipe? does this contain the faulty potentiometer and tuning valve ? thanks
 
Can I ask other fsi owners if your car also has a symptom of nearly stalling, running very rough when oil cap ( at the top of engine ) is taken off?

I'm not a FSi owner but that's normal. Most modern engine have a closed circuit breather system which feeds crankcase fumes into the air intake system. Removing the oil filler cap allows masses of unmetered air (it enters after the MAF sensor) into the cylinders via the breather system causing a very weak mixture.

Cheers Spike
 
thanks for your reply mjhamilton, so can i replace the throttle body i.e the motorised unit inbetween the MAF sensor and EGR Pipe? does this contain the faulty potentiometer and tuning valve ? thanks

The entire intake system including vacuum valve and potentiometer containing the air flap is what is needed... The engine needs to be supported and the engine mount removed to swap out

Pretty labour intensive job
 
car is still in the garage, trying to figure out why it stalling once it warms up, have had all the coilpacks and sparkplugs changed and it has definitely made the engine more 'refined' but it still starts to sputter and stall once hot. I recall that i briefly fitted a EGR blanking plate from ebay (wrong one was meant for diesel only), now on removal i did not refit the EGR valve gasket thus causing a vacuum leak ? I can see condensation around the egr connecting pipe bubbling when the car is revved i have now ordered the gasket and will update if this fixes the hot stalling issue.
 
I'm not a FSi owner but that's normal. Most modern engine have a closed circuit breather system which feeds crankcase fumes into the air intake system. Removing the oil filler cap allows masses of unmetered air (it enters after the MAF sensor) into the cylinders via the breather system causing a very weak mixture.

Cheers Spike

As Spike said :) . Have the same in 2 other cars and one brand new
 
egr blanking plate

hi shery119. i am assuming you are using the "dimpled" egr plate. could i ask where you managed to source said item? (as i am currently contemplating the same mod.) thanks
 
I have my "old" egr pipe if this could be modded by someone into a blanking plate?
 
hi shery119. i am assuming you are using the "dimpled" egr plate. could i ask where you managed to source said item? (as i am currently contemplating the same mod.) thanks

Sorry i meant to say that i bought the wrong EGR blanking plate and on removal of this plate i failed to re-fit the EGR Gasket which i have since misplaced thus causing a vacuum leak, i am not sure if anyone sells the dimpled egr plate for the FSI .
 
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