1.9 TDi ASR light and misfire/juddering

Hi

A few weeks ago this problem started, turning the car off and on at the ignition would fix it for a while but it always came back. Slowly getting more and more frequent until now, after a few minutes of driving, the light's on and the engine runs really rough.

I've looked around online and the most likely cause seems to be injectors, or the injector loom. I haven't had the fault codes read, if there's anyone nearby who has a reader I'd be happy to for a reading with beer :)

I thought I'd try replacing the loom as it seems like the most likely cause and pretty cheap, until I went to a VW dealer who told me it would cost over £500. I'm sure this is wrong so I wanted to get one online but I have no idea what the part code is (or what my engine code is).

Any help with how to figure out my engine code, fault reading, the part I need, any other advice would be awesome.

Other threads I've read (hope it's OK to link to other forums, these might be useful links for someone),
Bora PD 130 Misfiring and ASR light coming on.
[Mk4 Golf] Judder/misfire on Golf TDI 150 - Engine, Tuning and Performance - uk-mkivs
http://www.tyresmoke.net/forum/topic...n-you-help-me/

Cheers

welcome. look in the boot, under the carpet near the spare, you should find a label with all the cars codes on it. the engine code will be 3 letters. it is also on the cover for the timing belt, but often destroyed too much to read. the same label as in the boot will also be in the service book. i presume its a pd tdi though, rather than a rotary pump. if so, then the loom is a usual culprit. they are about 55 quid from a dealer. don't buy one off ebay, you want a genuine one.

if you can't find the engine code, take a photo of the engine and we can tell from that what it is.

Thanks for the quick reply, I found a few codes, AJM, DRW, LA5W, CM... I'm guessing the engine code is AJM? Is that the one where it's common for the loom to fail?

The guy at the parts desk must have been wrong then if he reckoned over £500 for the loom. I'll phone some other dealers tomorrow and see what they say.

yes, ajm is a pd, so try a new loom first. rare for injectors to go but the looms do break down over time. about an hour to fit, just remove the rocker cover and extract it.

Thanks, I'll let you know how I get on...

Does the car run rough when the ASR light is on and is ok when it is off?

If so it could be quite bizarrely an ABS sensor fault. The ASR is quite a crude traction control system that works by cutting engine power. If you have a duff ABS sensor and the ABS system is being fed duff information it may be activating the traction control by sending a "cut the power" signal to the engine ECU.

Before you do anything (spend money) get it properly read for fault codes and or have someone look at the wheel speed measuring blocks whilst logged into the ABS system. I'd help but you are not close.

Very occasionally it's run rough without the ASR light coming on but usually (probably 95%+) the light comes on with the juddering. I've also tried disabling the ASR using the button on the center console as soon as I've started the engine but that doesn't stop the fault happening. But I guess if it was a faulty ABS sensor then that wouldn't affect it.
A fault code would help, if there's anyone nearby... there's a beer reward!:beerchug:

Otherwise I'll have to try a new injector loom and take it from there.

Update...

I've replaced the injector loom and driven for about 30 minutes so far without any sign of the fault. I'll be convinced it's fixed after a couple of weeks but so far so good.

A re-cap of the info in case anyone else has the same problem,

Engine: AJM 1.9TDi
Part: Injector loom/harness V038 971 600

...and if you like doing things properly - the rocker cover bolts should be tightened to 10Nm in this order...

Attachment 24807

The gasket only comes in a kit including a new rocker cover at £160 from VW. I used the original with some blue sealant on the corners.

Hope that helps someone and I'll let you know if the fault comes back.

thats good news. its a strange one that they don't do a gasket by itself. i had to do a loom and the injector seals on one last week, in a beetle. i got a payen gasket from my factors for about a tenner.

It's been over 1000 miles and still no sign of the fault - pretty conclusive :biglaugh: