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VW Caddy 2.0 BST 2006 - Bad starting - Fixed #

Posted by Kev Gundry on September 7, 2010, 4:28 pm

Year of Manufacture *: 09/2006
Engine Size and Code *: 2Litre BST
( Optional ) ECU Type: EDC16u1
( Optional ) Scanner Used: KTS

Hello all

Chassis no: WV1ZZZ2KZ7X020777

I have the above vehicle in the workshop at the moment, it has come in for bad starting. i carried out the basic checks first i.e. air in fuel system etc. and i have traced the fault to the glow plug control and it's a bit of a head scratcher.

if i go in to the Ecu with the KTS i can actuate the glowplug relay but they will not operate when the ign key is cycled. i suspected the coolant temp sensor but it appears ok also the fuel temp sensor if i disconnect both the fuel and coolant sensor the glow system will work.

if i look at live data the oil temp is about 12 deg c above the coolant and fuel temp. from the info i have the oil temp is taken from the oil level/temp unit in the sump is this a red herring or my fault i have checked the wiring to this component and also tried swapping it with a known good one. i am reluctant to send it to the dealer without doing my best. any ideas?

Kev Gundry

Re: VW Caddy WV1ZZZ2KZ7X020777

Posted by aidan birley <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT2879' width='330' height='300' border=0 style='border:none;'> on September 7, 2010, 6:40 pm, in reply to "VW Caddy WV1ZZZ2KZ7X020777"
Aidan Birley

Kev

On a 2006 vehicle, it is unlikely that it would need glow plugs for cold starting in current ambient temperatures. Many current systems wont switch glow plugs on for cold starting if temperature is over 5 C .

I assume this is a EDC Pump as opposed to PD ?

I personally would check pump timing and cranking speed next.

Re: VW Caddy WV1ZZZ2KZ7X020777

Posted by Kev Gundry <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5245' width='330' height='300' border=0 style='border:none;'> on September 7, 2010, 9:21 pm, in reply to "Re: VW Caddy WV1ZZZ2KZ7X020777"
Kevin Gundry

Aidan,

thank you for the reply. It is a PD engine. i have checked the timing and scoped the cam and crank sensor's as well and they are ok.

i will keep plugging away and hopefully get a result

Thanks

Kev Gundry

Re: VW Caddy WV1ZZZ2KZ7X020777

Posted by aidan birley <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT2879' width='330' height='300' border=0 style='border:none;'> on September 7, 2010, 10:02 pm, in reply to "Re: VW Caddy WV1ZZZ2KZ7X020777"
Aidan Birley

Kev

Is this cold or hot start issue? is the fuel good ?

There are low pressure supply tests for the PD, but I am not familiar enough to advise.

The 1.9 PD had vacuum throttle flap sticking issues that gave start problems, but not sure it applies to your engine code.

Still don't think this will be a glow plug issue.

Cheers Aidan

Re: VW Caddy WV1ZZZ2KZ7X020777

Posted by Kev Gundry <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5245' width='330' height='300' border=0 style='border:none;'> on September 8, 2010, 8:32 am, in reply to "VW Caddy WV1ZZZ2KZ7X020777"
Kevin Gundry

Hi Aidan,

I have tried it this morning after leaving it overnight, and actuated the glowplugs with The Kts, i also put a amp clamp around the glowplug feed to make sure they operating, then i cranked the engine for about 30 seconds before it started.

Once it has been started it fires up first time it's got to be air ingress in the fuel lines.

I also checked the intake flap prior to starting just to be sure. It will be something daft i'm sure

Thanks

Kev Gundry

Re: VW Caddy WV1ZZZ2KZ7X020777

Posted by Mark Carter <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT1428' width='330' height='300' border=0 style='border:none;'> on September 8, 2010, 8:50 am, in reply to "Re: VW Caddy WV1ZZZ2KZ7X020777"
Mark Carter

Hi Kevin,
have you checked the Pre-feed pump pressure and the cavity pressure in the head?
If so what where the readings?

Regards Mark

Modern cars, Its all wizardry and witchcraft

Re: VW Caddy WV1ZZZ2KZ7X020777

Posted by Kevin Gundry on September 8, 2010, 10:54 am, in reply to "Re: VW Caddy WV1ZZZ2KZ7X020777"
Message modified by board administrator September 8, 2010, 2:05 pm

Hi Mark,

No i have not could you please enlighten me? i am in the process of checking the fuel lines at the moment. i have just checked the filter housing. checking the fuel pressure was the next step, if you have any info on this i would be very grateful.

Thanks

Kev Gundry

Re: VW Caddy WV1ZZZ2KZ7X020777

Posted by Mark Carter <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT1428' width='330' height='300' border=0 style='border:none;'> on September 9, 2010, 7:37 pm, in reply to "Re: VW Caddy WV1ZZZ2KZ7X020777"
Mark Carter

There is a test port on the tandem pump,

KOEO = 0.5 bar approx

KOER = about 3 bar at idle rising with Rpm.

Regards Mark

Modern cars, Its all wizardry and witchcraft

Re: VW Caddy WV1ZZZ2KZ7X020777

Posted by Bryan Smith <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5330' width='330' height='300' border=0 style='border:none;'> on September 9, 2010, 9:36 pm, in reply to "Re: VW Caddy WV1ZZZ2KZ7X020777"
Bryan Smith

Hi Kevin
Watch this article on Autoinform. Frank starts on about mechanical problems but ends up explaining how to check the pump.

http://content.yudu.com/A1dxye/AI-2/resources/6.htm

HTH's
Bryan.

Fixed #

Posted by Kev Gundry on September 10, 2010, 10:40 am, in reply to "Re: VW Caddy WV1ZZZ2KZ7X020777"
Message modified by board administrator September 10, 2010, 3:21 pm

Hi Guy's

Thanks for the help on this one. It was indeed low fuel pressure , removed injectors and found one of the seals worn, replaced all the seals and the adjuster (nut and set screw)re-built and tested ok. glad to see the back of this one to be honest got there in the end with the help of you all?

Thanks

Kev Gundry

P.s. bryan, i will set down with a beer toight and watch that link.

Fixed #

Posted by Mark Carter on September 10, 2010, 11:34 am, in reply to "Re: VW Caddy WV1ZZZ2KZ7X020777 ***Fixed***"
Message modified by board administrator September 10, 2010, 3:21 pm

sounds good, did you follow the re-set procedure for the set screw and lock nut?

Regards Mark

Fixed #

Posted by Kev Gundry on September 10, 2010, 1:23 pm, in reply to "Re: VW Caddy WV1ZZZ2KZ7X020777 ***Fixed***"
Message modified by board administrator September 10, 2010, 3:21 pm

Hi Mark,

I did indeed, using a dial gauge on the screw until it's at the lowest point then screw the adjuster in until resistance is felt then back 180 deg then lock off the nut and tighten to 30nm

at least that is the info i have on ESI

Thanks again and have a good weekend

Kev Gundry

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