2009 TDI HPFP Fun

[greengeeker]

Would you have any recourse with VW on this if it is due to the intercooler icing/condensation? Long shot but thought I'd ask.

[sprstu]

I dont think VW has done anything for Icing in the past, they have installed a weird new uppipe for some people but if there is a failure your SOL. Ill check around on TDI club further and see what people say.

In the event I have a bent rod (or 4!!!) would it make more sense to source a new longblock or used engine complete?

[kustomizingkid]

Mn what a bummer... Hopefully its not something major.

[sprstu]

Super fun time.

After pulling the GP and cranking it over I did have water puff out of 3 cylinders. Nothing like a stream or anything but a noticeable amount shot out, stopped after 5-6 revolutions. I put the plugs back in and tried to fire it, still no start.


Back in the engine bay to check all connections and the fuel rail for leaks, everything seems ok. I then pulled the intake swivel valve to its fully open position, there was then the sound of locks opening inside the manifold.


Full glow plug cycle and cranked it for 5 seconds, it then stumbled to a start and ran rough for 3-5 seconds and once everything pressurized is started to idle as normal.


I drove it for about 45min around town and everything seems normal. I can not say for sure what was the exact cause but going through all of that fixed the issue. Im sure I depressurized the fuel system when I opened the filter and it would have fired over after cranking when I put the GPs back in so the swivel valve may have done nothing, still didnt hurt to try.




Short form:


No start out of the blue
Pulled the fuel filter and meter valve to check for metal, all clean as you would expect
Pulled the lower Inter Cooler hose and poured out a few ounces of water
Pulled the glow plugs and turned the engine over, water puffed out of 3 cylinders
Cranked but would not fire after reinstall of glow plugs
Pulled the Swivel Valve to full open
Stumbled and started runs with a clean idle

[Kriesel]

2Micron (on TDIClub), has a valve he's been making to drain the intercooler. Not sure how easy it is to get one, but look it up, or make one:

http://forums.tdiclub.com/showpost.p...postcount=2915

http://forums.tdiclub.com/showpost.p...postcount=3214

[greengeeker]

Well that's a relief! There are a lot of stories of water ingestion on the common rails but they typically happen while running and the effect is a serious stumble and rough running for a few seconds.

Based on your post above it does sound like your intake throttle might have been preventing air from getting into the engine...so your description of 'no compression' was actually very accurate if there was no air in the engine to compress.

Anyway, glad you got it sorted out. You can thank your low pressure EGR circuit for all the condensation in the charge air system. I think you know the foolproof fix to that issue.

[MisdemeanorMatt]

Bullet dodged, glad it all worked out.

[sprstu]

Malone stage 2 and some off-road pieces (sitting in my garage now) are in the works.

[isonic]

Wow, really glad that all worked out Stu. That could have been bad!