Golf Mk6 1.6 TDi issues :(

[MrO]

Morning folks,

im new here and been having a scout round the forum and already finding some useful stuff (it’s a lot bigger forum than what I’m used to so still finding my feet)

My Golf has turned into a bit of a nightmare over the last month....details below. Any help / advice going forward would be appreciated.

first a bit of info:
————————-

61 - 2011

59500 miles - I bought it as a one owner car from VW with 27000 miles 2.5 years ago

I stupidly had the emissions update done before I knew better

1/ About 4 weeks ago I had the EGR replaced under warranty - I was 3 weeks away from the 24 month warrant6 running out.

2/ The less than a week after I had an injector clamp bolt snap and two injectors pop out.

3/ Now the engine is running very rough on tick over when cold, the car can be felt physically shaking. Also I’m noticing some ticking noise when the engine is under load from around 1500 - 2000 rpm in 2nd and 3rd gear. I’m not sure if this has always been happening or I’m just hearing it because I’m listenig more....

Q1/ Did the injectors suffer some damage when the clamp bolt snapped?

Q2/ Is 59500 miles a normal mileage to replace injectors?

Q3/ If the injectors do need replacing and I get them changed what issue am I likely to encounter next?

thanks in advance for any advice / help.

MrO

[philipharmes]

It sounds like whoever replaced the injectors didn't do a very good job.

The ticking sound is almost certainly combustion gas escaping past the injector seals, the lost pressure will be causing the missfire.

The escaping gas will be damaging the injector seats so need attention ASAP.

I would take it to a diesel injection specialist who has dealt with this engine before.

[MrO]

I forgot to mention that the misfire / lumpy tick over goes away quite quickly.. but when it is doing it’s misfire thing sometimes I can smell what I thought was diesel / oil coming through the air vents. Will this be the combustion gas escaping?

It sounds like whoever replaced the injectors didn't do a very good job.

The ticking sound is almost certainly combustion gas escaping past the injector seals, the lost pressure will be causing the missfire.

The escaping gas will be damaging the injector seats so need attention ASAP.

I would take it to a diesel injection specialist who has dealt with this engine before.

[Crasher]

I have never known the injector bolt to randomly snap, have they been out?

[MrO]

When it snapped the RAC who towed me said it was a common problem. The bolt when replaced gets over torqued and then fractured, then cracks and finally snaps. The recommendation for the bolt torque is 8nm + 180°

Here is a photo of my snapped bolt (if I can upload it)

[Crasher]

If the injectors have been out (?) I imagine the bolt was re-used as it should be replaced.

[Crasher]

Can’t see why that happened

[MrO]

Two injectors got replaced by VW before I bought the car, it showed up on their check - which I was surprised about at 27000 miles.. and apparently if the clamp is slightly over torqued it eventually snaps.


i’ve got some more info that might help diagnose my tickover issue:

a friend had a look to see to see what he thought was causing the tickover issue - and he spotted some smoke coming from the area behind the DPF. He said it could have been something not put back together properly after VW replaced the EGR valve. I took it back to VW so they could check but they said they couldn’t see any smoke. Yesterday morning I opened the bonnet before starting the engine and then went to have a look as soon as the engine was running... I seen the smoke. So I’m now wondering if it only appears when the engine is cold and if it gets resolved will it solve the tickover problem?

[philipharmes]

I forgot to mention that the misfire / lumpy tick over goes away quite quickly.. but when it is doing it’s misfire thing sometimes I can smell what I thought was diesel / oil coming through the air vents. Will this be the combustion gas escaping?

On the cylinder/s where gas is escaping, compression is being lost & the cylinder/s won't fire properly.

As the engine runs, heat will be generated & the faulty cylinders will start to fire ok.

But while misfiring, diesel will be escaping with air giving you the diesel smell.

Once running, hot exhaust gas will be escaping & damaging the injector seats.

[Crasher]

We have experienced problems with the thread from the convoluted EGR pipe going up to the manifold, the threads often strip when you take out the bolt and installing two Time Serts in situ is awkawrd, so it is possible the flange is leaking. Smoke would come on on the carsright in left left rear corner of the engine bay as you look at it from the front.