A2 TDi 75 160k miles, smokey on cold start. Is it normal?

philward

Member
Thanks @spike I only became aware of this problem after reading the Glow plug diagnosis thread, but that was some time ago. It never occurred to me to check if I already had 5V plugs in the engine. Checked my receipt, they were fitted 04/2016, I guess however they failed within days of being fitted? In @sco 's case they appeared to break up after about 3 days.
Yes I have been very lucky, only a small slither of the thin skin of the tip appears broken off, hopefully that was years ago and not when I removed the plug. How do you get a scope in to check please?
@kp 115 , I did indeed input my reg at the time, it's the first thing I do if I buy from ECP. There was however a historic database issue that resulted in this problem. Being aware of this problem and the consequences, on this occasion, I checked ECP listings with Fibi parts finder, AutoDoc, Bosch web site and EBay. Interestingly the new plugs are a different color code but having been caught by this once, and apparently having got away with it, I'll take one out and check it is healthy.
 
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PlasticMac

Member
If a supplier, as here, supplies an incorrect part, due to an error in their database, do they have any liability for damage or, at least foc replacements?
I mean legally, not morally.
Mac.
 

spike

Member
I think the previous reported failures related to Bosch 5v glow plugs so it's possible they may be a bit more fragile than the Beru equivalents when they overheat.

UPDATE
Just to make my comment clear, I was guessing that the Bosch 5v glow plugs specifically designed for the 90 TDi may burn out quicker than the Beru equivalents when subjected to 100% voltage overload if incorrectly fitted in a 75 TDi engine.

I've always used the correct Bosch glowplugs in my 75 TDi by choice

Cheers Spike
 
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Louisp

Member
Hi all, this thread is very comforting as I have the same issue but it has now caused something more severe to happen on cold starts.
I get the smoke that clears once she has run for a minute but even on idle now the engine (AMF 55KW) does what I can only describe as a hiccup and then runs like on 2 cylinders and throws plenty of lights on the dash ABS, Flashing ((!)) in the centre, break disk and lots of noise. on stopping and restarting it will do the same thing and it happens faster if I load the engine from cold i.e. set off. Once warm there is no issue.

I tested the back of each glow plug with a jump lead attached to the 12v live battery and got no spark from them but got one from the chassis I accidentally touched. I think all the plugs are dead. The engine throws quickly to start-up so not sure another earth would help.

Any ideas apart from swap the plugs?

did a cold start at 5 degrees and 10 degrees and it's the same issue. I've an intercooler coming as the car goes into limp mode if driven hard on the motorway so I'm assuming there is a leak there as well.
 
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Louisp

Member
I think the previous reported failures related to Bosch 5v glow plugs so it's possible they may be a bit more fragile than the Beru equivalents when they overheat.

Cheers Spike
What brands of glow plugs would you recommend? I can get Beru (438440175) Hdria, Bosch, NGK or BERU (438440075) which is from cheapest to most expensive from eurocarparts which makes them cheaper than darkside. The only odd thing is that I don't know what brand Darkside sell and there are 2 Beru plugs with different numbers being the cheapest and most expensive.
 

Howey

Member
Hi all, this thread is very comforting as I have the same issue but it has now caused something more severe to happen on cold starts.
I get the smoke that clears once she has run for a minute but even on idle now the engine (AMF 55KW) does what I can only describe as a hiccup and then runs like on 2 cylinders and throws plenty of lights on the dash ABS, Flashing ((!)) in the centre, break disk and lots of noise. on stopping and restarting it will do the same thing and it happens faster if I load the engine from cold i.e. set off. Once warm there is no issue.

I tested the back of each glow plug with a jump lead attached to the 12v live battery and got no spark from them but got one from the chassis I accidentally touched. I think all the plugs are dead. The engine throws quickly to start-up so not sure another earth would help.

Any ideas apart from swap the plugs?

did a cold start at 5 degrees and 10 degrees and it's the same issue. I've an intercooler coming as the car goes into limp mode if driven hard on the motorway so I'm assuming there is a leak there as well.
So
Hi all, this thread is very comforting as I have the same issue but it has now caused something more severe to happen on cold starts.
I get the smoke that clears once she has run for a minute but even on idle now the engine (AMF 55KW) does what I can only describe as a hiccup and then runs like on 2 cylinders and throws plenty of lights on the dash ABS, Flashing ((!)) in the centre, break disk and lots of noise. on stopping and restarting it will do the same thing and it happens faster if I load the engine from cold i.e. set off. Once warm there is no issue.

I tested the back of each glow plug with a jump lead attached to the 12v live battery and got no spark from them but got one from the chassis I accidentally touched. I think all the plugs are dead. The engine throws quickly to start-up so not sure another earth would help.

Any ideas apart from swap the plugs?

did a cold start at 5 degrees and 10 degrees and it's the same issue. I've an intercooler coming as the car goes into limp mode if driven hard on the motorway so I'm assuming there is a leak there as well.
sounds like you have an injector going down, probably no1 and probably a loose connection at the multiplug on injector wiring loom, have you ever had a fault code read?
 

Louisp

Member
So
sounds like you have an injector going down, probably no1 and probably a loose connection at the multiplug on injector wiring loom, have you ever had a fault code read?

Thanks for the advice, I’ll get the fault codes read off and see what it says. OK schoolboy error I lent my VAGCOM cable to @depronman but I have a bluetooth dongle on my other car. Unfortunately when connecting it to the A2 and using the iPhone app "Car Scanner" it does not read the codes from the car. Anyone have an idea of what app might work with a bluetooth dongle on android or iOs and can read the A2 codes?
 
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kp 115

Member
What brands of glow plugs would you recommend? I can get Beru (438440175) Hdria, Bosch, NGK or BERU (438440075) which is from cheapest to most expensive from eurocarparts which makes them cheaper than darkside. The only odd thing is that I don't know what brand Darkside sell and there are 2 Beru plugs with different numbers being the cheapest and most expensive.
Hi Louisp,
My Glowplugs from Darkside Developments were Bosch if that’s any help.
1613837005143.jpeg
1613837005143.jpeg

Original Beru & new Bosch plug.
Hth
Keith.
 
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PlasticMac

Member
Thanks for the advice, I’ll get the fault codes read off and see what it says. OK schoolboy error I lent my VAGCOM cable to @depronman but I have a bluetooth dongle on my other car. Unfortunately when connecting it to the A2 and using the iPhone app "Car Scanner" it does not read the codes from the car. Anyone have an idea of what app might work with a bluetooth dongle on android or iOs and can read the A2 codes?
Most app based scanners are generic, so don't support VAG specific codes. OBD Eleven does support VAG codes. Good on Android, recently added ios version, so check it out. Not cheap though. Old laptop, KKL lead, and VCDS Lite would be cheaper.
Mac.
 

Louisp

Member
OK scanning the codes doing a clear and running the engine has bought up that cylinder 2 is misfiring with electrical issues:

18075 - PD Unit Injector; Cylinder 2 (N241)
P1667 - 35-10 - Electrical Malfunction - Intermittent
16686 - Cylinder 2
P0302 - 35-10 - Misfire Detected - Intermittent

doing a monitor of the injectors showed the following:
-1.88 mg/str Injection Quantity Deviation Cyl. 1
2.99 mg/str Injection Quantity Deviation Cyl. 2
-1.46 mg/str Injection Quantity Deviation Cyl. 3
14.0 Injector Status Cylinder 1
14.0 Injector Status Cylinder 2
14.0 Injector Status Cylinder 3
9.0 Switch Time Deviat. Cylinder 1
3.0 Switch Time Deviat. Cylinder 2
4.0 Switch Time Deviat. Cylinder 3

so does the injector need a refurbish or is it the injector loom replacement needed?
 

Howey

Member
OK scanning the codes doing a clear and running the engine has bought up that cylinder 2 is misfiring with electrical issues:

18075 - PD Unit Injector; Cylinder 2 (N241)
P1667 - 35-10 - Electrical Malfunction - Intermittent
16686 - Cylinder 2
P0302 - 35-10 - Misfire Detected - Intermittent

doing a monitor of the injectors showed the following:
-1.88 mg/str Injection Quantity Deviation Cyl. 1
2.99 mg/str Injection Quantity Deviation Cyl. 2
-1.46 mg/str Injection Quantity Deviation Cyl. 3
14.0 Injector Status Cylinder 1
14.0 Injector Status Cylinder 2
14.0 Injector Status Cylinder 3
9.0 Switch Time Deviat. Cylinder 1
3.0 Switch Time Deviat. Cylinder 2
4.0 Switch Time Deviat. Cylinder 3

so does the injector need a refurbish or is it the injector loom replacement needed?
I removed the loom and the wiring connections from the plugs and retightened them, then with a little superglue resecured and refitted.
Also removed egr and cleaned it up (wanted to do inlet manifold but it looks a bit of a mission) so far all good a few thousand miles on
 

Louisp

Member
I removed the loom and the wiring connections from the plugs and retightened them, then with a little superglue resecured and refitted.
Also removed egr and cleaned it up (wanted to do inlet manifold but it looks a bit of a mission) so far all good a few thousand miles on

Did the rocker cover go back on ok? I am told it warped and can seep oil at the back over time and getting it back on perfectly can be impossible.
 

philward

Member
Did the rocker cover go back on ok? I am told it warped and can seep oil at the back over time and getting it back on perfectly can be impossible.
I've had no end of trouble with leaking rocker covers, getting a new one didn't fix it. For best results use the Audi recommended tightening sequence and remove the EGR before you start torquing down.
 

philward

Member
Things are looking good with my engine. Removed the new plug from the cylinder that had the semi blown up 5v plug in to check condition, it looks fine.
I still haven't worked out how to bore scope a diesel though?
 

spike

Member
Things are looking good with my engine. Removed the new plug from the cylinder that had the semi blown up 5v plug in to check condition, it looks fine.
I still haven't worked out how to bore scope a diesel though?

How about the glowplug holes = or is the scope too large

Cheers Spike
 

Louisp

Member
I've had no end of trouble with leaking rocker covers, getting a new one didn't fix it. For best results use the Audi recommended tightening sequence and remove the EGR before you start torquing down.

Have you a link to the tightening sequence? The smoking is now gone and she’s running loads better with the new wiring harness and glow plugs
 
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