2006 Passat 2.0 tdi 140bhp Estate

[hazza171]

First of all hello new to site and lots of good info.

i have recently got a new VW Passat as above .

within 2 weeks bad running problems and in limp mode already.

1st Bad starting takes 20-30 seconds sometime 3-4 trys holding key to start.

2nd AA came out due to none start said it was the injectors so went to VW for Recall warranty and they said not the injectors was the wiring loom.
Had it fitted at £207 joke. upon collection it was starting and running as bad in LIMP mode again and they said this was now the Inter-cooler AKA front air charger .

would a hole in the inter-cooler cause this bad starting and also running in LIMP mode he said there is a hole in the plastic housing size of a tennis ball ?.

Ordered a new inter-cooler but now worried this may not be the fault for bad start .

Any help would be great.

Thanks James.

looking forward to a good VW chat :)

[Flash2]

Hello James, welcome to the forum.

I'm not sure a hole in the intercooler would put your engine into limp mode, but it would drive like it was. The engine performance would be very poor because all the turbo's boost pressure would be escaping through the hole.

You don't happen to know any of the trouble codes that your engine had, do you? Did the dealer not tell you you had a problem with the boost pressure system (intercooler) when they done the injector wiring repair. It would be a bit odd if they didn't mention it to you until you returned the car and complained. If there is a hole the size of a tennis ball in the intercooler, there is no way the could have missed it during test drive after fixing the injectors. (assuming they did a test drive, of course)

At the end of the day, if there's a hole in the intercooler then it needs to be replaced. So I'd advise fitting the new one, clear the trouble codes and test drive the car. Just make sure it is a hole that's not supposed to be there and not one of the holes where the hoses attach, because those holes are about the size of a tennis ball too.

Jim.

[hazza171]

Thanks for the reply Jim.

Don't have the codes will be getting them soon as i get my code reader .

to be honest i felt a little fobbed of by them they just wanted the car gone .
all i got was a quote for £301.22 part and £315 lab .

Does anyone have a walk through for the inter-cooler R&R.

i would really of liked the full diagnostic print out of the first code which stated 3 injectors down.
they fitted a new loom and that has removed these codes apparently but now the lights back on
and they say its due to the inter-cooler also would of liked a print out of this diagnostic reading aswell
but i will know more when i get the codes.

Thanks James

[Flash2]

You can ask your dealer to give a print out of the diagnostic log from their machine. Or ask them to e'mail you the digital file (because the print out will use a full ream of paper) so you can review it on your PC.
Their diag machines automatically log all the trouble codes in the car and also what tests they done using the machine. The logs are held on a server at VW technical center, so they can still access them long after the job was done.

Jim.

[hazza171]

Thanks Jim.

i have emailed over to vw regarding my scanner print out and awaiting a reply :) fingers crossed.

does anybody know the best way to remove and replace the intercooler .

does it require the front bumper removal and front end taking off or can you removed the fans and rad out putll it towards the engine (back of car) ??

has anybody done this if so whats the best plan of action ??

[RichardSEL]

Post your scanner's saved file here too?

[Quatrelle]

Just a thought - I was under the impression that the loom should have been replaced when the injectors were originally changed under warranty? If it was, the new one didn't last very long.

It's good that they're throwing your money at it - how on earth could they say it's one thing, charge you for it and then say 'ok, no it wasn't that', we'll try something else. Why didn't they do a scan before they started changing things?

I think I'd be knocking on their door asking for my £207 back please. Sounds like a rip-off to me.

I'm guessing you didn't buy the car from a VW dealer? If you did, didn't they give you any sort of guarantee with it?

[hazza171]

Yes was done under the recall 3 years ago they will only guarantee parts for 2 years so basicly I can expect to be replacing this loom in 3 years . Was from aut#tradrr so no warranty .they did a scan that said it was the loom chanhed that but said there is a hole in the intercooler thats the new problem . I will be able to see in more detail when I get the scan results back if its hot the same code I will be nocking back on for my 207 back .

[hazza171]

UPDATE .

Well had a fun Saturday morning nice 3 Hours taking the front off and replacing the intercooler was a nice job simple but looks worse then it was.
Car runs abit better as now not losing it boost due to snapped intercooler mounting .

I have ran a code check and got 7 codes below.

10501 ?? can not find any information
17668 PD Unit Injector Cylinder 1
17671 PD Unit Injector Cylinder 2
17672 PD Unit Injector Cylinder 2
17674 PD Unit Injector Cylinder 3
17675 PD Unit Injector Cylinder 3
17678 PD Unit Injector Cylinder 4

Deleted the codes and went to blackpool for a drive 80Mins each way for a good run and it ran heavy around 18-20 MPG at 70 in 6th
Then got home and ran a diag test again and got all 7 codes again.

Still starting like S#it but runs better i think it is still in limp or well under power .
idle after 20 mins went back to shaking the car badly .

Whats anyone's opinion ?

Thanks for all the replys.