A few TDI Problems - What to try next

[mrapoc]

Hello!

The suspect is a 1.9 gttdi AJM 115 @ 160k on the clock.

What is the issue?

• Struggling to get any higher than 40mpg without really driving slow!
• Really rough cold starts

What have I done so far?

• Turbo cleaned out and actuator replaced due to rust/limp mode - car doesn't go into limp anymore!
• Changed to genuine MAF from crap aftermarket one - Pulls a lot nicer!
• Cleaned the EGR - Not noticeable yet, however something makes it shudder at 2k revs
• Changed 3 out of 4 glow plugs...1 is kinda stuck in there...the "bolt" has come loose...leaving it be for now - car still starts crap (cold)
• No errors show on my free version of vcds lite. Might be able to get a vcds lite license if it helps?
• Temperature gets to 90 in a respectable amount of time and stays there
• Oil, Oil filter, Air filter, Fuel filter was changed about 4-5 months ago
• Changed most of the vacuum lines from the frayed material to new pipes - not sure if the line going to turbo is 3mm or 4mm

Any help or suggestions would be very gratefully accepted.
Its a lovely car but the main issue is only getting 100 miles to £20-£25 and thats driving steadily!

[littco]

Sounds like a boost/ vacuum leak.

Check all connectors around the system and vacuum pipes.

[mrapoc]

Cheers mate. I have changed 3/4 of the vacuum pipes already. Not sure if the turbo should have a 3mm pipe or 4mm pipe going to it. So i havent done that yet.

Would it be an idea to ask a local garage to smoke test it? How much should I expect this to cost. Don't want this car to be any more of a money eating bottomless pit!

 

[mrapoc]

Drove up the m54 today. Stuck to 70mph all the way and managed to get 45mpg. Surely I can/should be getting more?

[mrapoc]

I'm getting a flat spot/shuddering at about 2k revs now too 

[mrapoc]

Cleaned the intercooler and noticed the MAP sensor has been messed with before...well. It had silicon sealant all over it. Also one of the screws looks badly rounded..If its anything to go by my MAF (non genuine) could this possibly be causing bad mpg? Worth prying off all the silicon and tapping the screw out to check?

 

I've changed the thermostat and temp sender (to a green one) anyway

[sprout99]

map sensor could be a problem.

on a past car that was causing me loss of power at about 2000 revs

[scarr89]

map sensor could be a problem.

on a past car that was causing me loss of power at about 2000 revs

+1

I cleaned mine and my flat spot, which was around 2500, disappeared.  This will take an hour tops, real easy fix if this is your issue.

[mrapoc]

Cool.

I've changed my MAF already and this helped.

Now I am experiencing loss of power at 2k/mpg issues too so i will check out my MAP too if this may be the case

[EsSeX dAn]

when ws it last serviced fella? how long have you had the car aswell? could be a timing issur