Replacement engine

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RUM4MO
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Re: Replacement engine

Post by RUM4MO »

Excellent, when it arrives you could gently clean it with brake cleaner, it is normally suggested that you sort of spray it in "indirectly" so as to minimise the chance of damaging it. Repeat that a few times, maybe 10 times to try to clean as much crap out of there as possible without resorting to using an aggressive solvent or crude mechanical means, I think is the plan according to what I've read.
littlepolo
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Re: Replacement engine

Post by littlepolo »

MAP sensor arrived. Gave it a clean with Halfords electrical cleaner and installed.

I was able to complete the TBA (060) OK but when I went to do the EGR (074) I could not click GO in Basic Settings because, I presume, it indicates Test Off in the rightmost box. The engine will start OK but is a bit lumpy at idle dipping down between 600 and then up to 680 or so. Temp was up to 90C and stable.

I tried again and when I went into 074 it said OK. Restarted the engine and it faltered and stalled. Went through the above (060) and (074) again with the same result. I cleared the EGR error code but it came straight back.

Sorry, meant to say after 074 completed OK there was no error code, just unable to idle (stalling). Starts OK.

Previous error code was P1404 EGR System Basic Setting not Performed.

Obviously the EGR is a factor in this. Have I missed something or is the EGR faulty?
Last edited by littlepolo on Thu Dec 14, 2017 4:11 pm, edited 1 time in total.
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alexperkins
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Re: Replacement engine

Post by alexperkins »

Can you post a screen grab of the VCDS faults?
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Re: Replacement engine

Post by littlepolo »

Please see update to post above. There are no error codes now.

Throttle body adapted OK. EGR adapted OK. Engine idled OK after TBA and before EGR adaptation. After EGR adaptation it stalls.

075 says Test Off.
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alexperkins
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Re: Replacement engine

Post by alexperkins »

It sounds like the TB isnt allowing idle properly. Is it sparkling clean? 650rpm is a bit low for idle. It should be closer to 800

The EGR adaption is a bit of a wierd one, as it can cause the engine to stall. I had the same behaviour on my brother in laws mk5 golf 1.6 FSI
littlepolo
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Re: Replacement engine

Post by littlepolo »

TB is very clean.

After MAP was installed and TBA completed (before EGR adaptation) it idled at 1100-ish from cold and then dropped down a bit as it warmed up.

The EGR adaptation triggered the stalling issue. How did you resolve the issue on the Golf?
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Re: Replacement engine

Post by alexperkins »

We had to replace the EGR and it has to be calibrated before the engine is started. Theres a procedure to follow or its toast
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Re: Replacement engine

Post by alexperkins »

http://wiki.ross-tech.com/wiki/index.ph ... Adaptation


Exhaust Gas Recirculation (EGR) Valve Adaptation
Most VW/Audi/Seat/Skoda gasoline engines with Exhaust Gas Recirculation (EGR)

Prerequisites (General):
Ignition ON
Engine OFF
Battery voltage at least 11.5 V

[Select]
[01 - Engine]
[Meas. Blocks - 08]
Select Group 074.
[Go!]
MVB 074.1: Min Position in Volts
MVB 074.2: Max Position in Volts
MVB 074.3: Potentiometer voltage
MVB 074.4: Adaption status: (Run/OK/etc)
[Switch to Basic Settings]
MVB 074.4: Adaption status: (Run) then it should change to (ADP OK)
[Switch to Measuring Blocks]
[Close Controller, Go Back - 06]

Special Notes:
For ECU's using ME 7.5, the coolant temp needs to be between 10 and 50 °C.
In case the adaptation fails switch OFF the Ignition for 30 Seconds, then switch it ON and try again.
littlepolo
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Re: Replacement engine

Post by littlepolo »

Thanks. That appears to have completed OK. What is 075 (I could not get it to run - Test Off)?

I'll try another throttle adaptation tomorrow and go for a drive to see if it settles down.
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alexperkins
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Re: Replacement engine

Post by alexperkins »

http://www.ross-tech.com/vag-com/m_blocks/070-079.html

Its to do with the EGR, but not something you would pay a great deal of attention to

Check you have no vacuum leaks as that can cause a poor idle.
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Re: Replacement engine

Post by littlepolo »

What is the correct material for the gasket on the throttle plate/EGR pipe joint?
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Re: Replacement engine

Post by alexperkins »

It has a proper gasket. I’ll get the part number
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Re: Replacement engine

Post by alexperkins »

Is it a BBY engine?
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Re: Replacement engine

Post by littlepolo »

alexperkins wrote: Thu Dec 14, 2017 7:36 pm Is it a BBY engine?
Yes, it’s a BBY.
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Re: Replacement engine

Post by littlepolo »

Got the EGR gasket set this morning and fitted them. Put my hand over the throttle body and the engine stalled so looks like no vacuum leak. Car runs OK when warming up but stalls when hot. I can just about keep it going and drive it but it's not really usable. No error codes.

When I replaced the EGR gaskets I checked that the plunger was moving with my finger and it seems OK.

Would it be worthwhile unplugging the EGR electrical connector to see if it runs when hot? (Edit: just tried that, it starts and stalls right away).
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