MY 3.2 swap mk4 is running like a bag of crap

Right, I give up ,this is doing my head in now. If I do't get this sorted soon the engine is coming out and I'm fitting a 150PD lump instead.

Tried 3 ECU's on it, all run the same, lumpy as hell.

Got brand new plugs (at a cost of 73) and i swapped a coil pack as one was cracked.

Exhaust isn't blowing and has all new gaskets.

Can't find any leaks on the inlet side either.

Head gasket was brand new before I fitted the engine. bores were mint (although I haven't checked the compressions yet)

It's doing a pathetic 24mpg, idles really lumpy, sometimes it won't even tickover. Sometimes it idles at 1100rpm, sometimes it's chugging away at 520 and making a horrible noise.

The only thing that I know for sure which could be "wrong" is the inlet pipe and MAF, as it's smaller than the R32 MAF housing I have. still waiting for a new hose off back order. MAF is brand new.

Friday,02,March,2007,17:15:34
VAG-COM Version: Release 607.3-UD

Control Module Part Number: 022 906 032 CP
Component and/or Version: MOTRONIC ME7.1.1G 6463
Software Coding: 0000132
Work Shop Code: WSC 00000
10 Faults Found:
19475 - Valve for Exhaust Flap 1 (N321): Open Circuit
P3019 - 004 - No Signal/Communication - MIL ON
16684 - Random/Multiple Cylinder Misfire Detected
P0300 - 008 - Implausible Signal - Intermittent
16690 - Cylinder 6: Misfire Detected
P0306 - 008 - Implausible Signal - Intermittent
16688 - Cylinder 4: Misfire Detected
P0304 - 008 - Implausible Signal - Intermittent
16685 - Cylinder 1: Misfire Detected
P0301 - 008 - Implausible Signal - Intermittent
16891 - Idle Control System RPM: Higher than Expected.
P0507 - 001 - Upper Limit Exceeded
17560 - Long Term Fuel Trim Additive Air; Bank 1; Range 2: System too Lean
P1152 - 001 - Upper Limit Exceeded
17559 - Long Term Fuel Trim Additive Air; Bank 1; Range 1: System too Lean
P1151 - 001 - Upper Limit Exceeded
17498 - Mixture Regulation; Bank 2; Range 2: Lean Limit Exceeded
P1090 - 001 - Upper Limit Exceeded
17497 - Mixture Regulation; Bank 2; Range 1: Lean Limit Exceeded
P1089 - 001 - Upper Limit Exceeded

Readiness: 0000 1001

that's the scan. been driving it for about 3 weeks since I last cleared the codes. when i clear the codes it runs even worse.

 

sounds really silly but you've not been hit by some crap fuel have you?

 

nah, it's been like this since I fitted it. I just can't get it to run smooth.

 

some odd air leak?

 

looks like you have faults with cylinder 1, 4 and 6, id say swap the coils around, ie 1 and 2, 3 and 4 and 5 and 6, erase the faults and re run the engine for a while, re check the fault memories and see if the fault for the cylinder missfire has changed

if so the coil packs are shot

 

also its showing the lean limit has been reached which shows its running to rich and it cant lean it off anymore, id say the misfire fault is the cause

 

got a few spare coils, once of which is brand new. will see if that takes away the misfire on all /any of those cylinders.

plugs indicate it's running fine.

coils could be suspect, seeing as one of them snapped in half when I tried to remove it!

 

dont wannt sound funny, but write down as well which ones have been swapped to where cos i bet thatll be really easy to forget after running it a few days

 

should only take 5 mins if that to register the faults

plugs might not be sparking so wont show signs really if they are new

 

tried a few different coil packs, still runs lumpy.

been playing with vag com doing some output tests, it would appear that the solenoid valve for the secondary air pump isn't working (i can't hear it clicking) and the same could be said of the VVT solenoid for the exhaust cam.

 

It’s easier to check for fuel trim and misfire faults using OEDB as you can check the actual values well before you will see a fault code. Fuel trim codes don’t show up until the cars completed a drive cycle so it can take weeks for the code to pop up.

 

it will run worse after you’ve cleared because the long term fuel trim will be brought back to 0 making the mixture even weaker, the more you drive the richer it will try and make the mixture until it flags a fault code because it’s gone beyond it’s maximum recommended trim level (can’t remember the limit off hand)

 

yeah, does better mpg once I've reset it.

might pull the bumper off tomorrow to fix that air pump valve and whip the manifold off to check for leaks. it's looking like it's got an air leak on the inlet side, causing the idle to be too high, and screwing up the mixture. possibly.

you can check fuel trim by looking at group 032

useful page

http://www.ross-tech.com/vag-com/cars/fuel-trim.html

I daren't check the compressions :-(

one thing that is concerning me is #3 spark plug thread. it felt awful when I nipped it up, like it didn't really want to be tightened, as if it was stripping the thread. so I'm now panicking that it's not sealing on that cylinder.

 

is that long term or short term fuel trim????

 

not sure. like you say, it takes a while for it to decide what to do with the fuelling.

that car is SO lumpy when I reset the codes that it will barely idle. sorts itself out after a dya or 2, but it's still lumpy as hell.

feels quick enough, but does crap mpg.

 

lean mixture will kill MPG

 

have a look tomorrow and clear the codes, run it but don't clear them, will bring the KTS up on Monday night

 

nice one, cheers.

will check the compressions tomorrow.....wish me luck that thread doesn't strip when I put the plug back in.

Got a spare head, but a days work and 80 on bolts and gasket isn't my idea of fun.

 

here's a thing. does the R32 have a bigger fuel pump than the 4motion?

 

Don’t thing so but may have a different fuel pressure regulator