103 TDI 2009 inttermitent stalling and failed starting

[Jamig]

Hey Guys

I have a strange fault with my Golf TDI, every now and then the car stalls and won't start or will after long persistent cranking. Then will function fine for weeks after without any issues at all.

I did take it to VW Specialist Garage to get fault codes checked and the Mechanic told me the intake manifold was showing an error due to the throttle sticking. Apparently this will get worse but the really bad news is to replace will cost around $1500!

Has anyone else experienced this and/or knows of a cheaper fix\solution or is this just standard VW?

Thanks in advance

J

[Lucas_R]

Yes the inlet manifold flap error is pretty common on the TDI's. Faulty inlet manifolds are pretty common on the Mk6 GTI's too. You can buy the parts you need online from a place like Darkside Developments (see link below) for about 1/2 of the price you can locally and that will save you some cash.

This inlet manifold is on special saving $180 GBP: Darkside Developments - Genuine 2.0 16v TDI PPD170 Intake Manifold

And here is a link to a product that claims to fix certain problems with the inlet manifold on the TDI's....might be worth looking into: A fix for CR TDI fault code P2015 intake manifold flap; implausible signal

[Jamig]

Yes the inlet manifold flap error is pretty common on the TDI's. Faulty inlet manifolds are pretty common on the Mk6 GTI's too. You can buy the parts you need online from a place like Darkside Developments (see link below) for about 1/2 of the price you can locally and that will save you some cash.

This inlet manifold is on special saving $180 GBP: Darkside Developments - Genuine 2.0 16v TDI PPD170 Intake Manifold

And here is a link to a product that claims to fix certain problems with the inlet manifold on the TDI's....might be worth looking into: A fix for CR TDI fault code P2015 intake manifold flap; implausible signal

Thanks Lucas_R. I'm going to take the car to another garage first for a second opinion but excellent advise. I'm also based in Melbourne Australia so anything this side of the water would be handy



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[TDIfan]

I just had a delivery from the Darkside guys this month which only took 5 days to land
That's including a weekend in between
They only use quality parts, worth waiting a few extra day for

[Jamig]

I just had a delivery from the Darkside guys this month which only took 5 days to land
That's including a weekend in between
They only use quality parts, worth waiting a few extra day for

That's incredibly quick from the UK, where in OZ are you?


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[TDIfan]

I'm in Perth
They use DHL so that doesn't really matter

[Jamig]

Cool, so Melbourne should be just as quick. How much was shipping?


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[Greg Roles]

OK, thing is the inlet manifold tumble flaps are just a cylinder filling to suit revs thing, they can't stall the car. The thing likely to stick is the EGR flap, diesels don't have a throttle flap. Your car will stall because of a fuel starvation, or the EGR flap is cutting the air flow, which is the most likely thing. Is the fuel filter OK / been serviced as per the schedule, they get filthy by 50,000kms.

Put in a can of diesel specific upper intake cleaner from Supercheap - they may have to order it in as most only stock the petrol one, and see if it helps.

[Jamig]

OK, thing is the inlet manifold tumble flaps are just a cylinder filling to suit revs thing, they can't stall the car. The thing likely to stick is the EGR flap, diesels don't have a throttle flap. Your car will stall because of a fuel starvation, or the EGR flap is cutting the air flow, which is the most likely thing. Is the fuel filter OK / been serviced as per the schedule, they get filthy by 50,000kms.

Put in a can of diesel specific upper intake cleaner from Supercheap - they may have to order it in as most only stock the petrol one, and see if it helps.

Car just had it's major 5 year/115,000km service so fuel filter was replaced then so I'm doubting the fuel filter. Maybe the EGR flap then? At least that sounds a bit cheaper then a complete manifold! So, does the cleaner your suggesting clean out the EGR valve or this is purely fuel related?

I experienced symptoms again today actually although this time i started car no problems and then half way through the journey the car started to loose power like it was stuttering or firing on 3 cylinders, I backed off the throttle and as it started loosing power it picked up again and then was fine.


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[Greg Roles]

EGR is sticking and starving the air I reckon, spray goes into inlet, fuel cleaners don't help as the fuel is injected directly to the cylinder. You can piuck up a new/used EGR valve off ebay UK for not much at all, but try and clean your one first!