Low of power in old Galaxy TDi after a few misfires yesterday

[GrahamW]

Hello All,

Yesterday my Mk1 R reg Galaxy TDi misfired a few times while trying to accelerate under 30mph around town. It was as though the engine cut out for a split second then carried on working. It has never done this before. There was no bang or anything like that, but a big lurch as the power cut.
The heater plug warning light now flashes permanently after the ignition has been turned on for about 35 seconds.

I have checked the fuel filter has no water in it, cleaned the battery terminals and have squirted contact cleaner on the electrical lead connections from the injector pump and today I took it on the road for a test. Around town it seemed to lack oomph, then on a 70mph bit of read it would not quite get to 70! 
I have a friend who has a code scanner but his device won't read the car's codes, perhaps as the car is too old.

I rang the local Ford dealers but they can only look at the car on Friday when I am working and refused to say how much they would actually charge to scan it - though they said the initial visual inspection would be free! 

Also, in case it is relevant, there has been a hissing sound audible from inside the car with the engine running for the last 18 months or so, and this is just discernible above the engine noise when looking under the bonnet.

Any ideas anyone? Thanks.

[insanitybeard]

Greetings!

If there's a hissing sound discernible then there's a chance there may be a vacuum leak (split/disconnected or rubbed through pipe etc) somewhere which could be messing up the boost control to the turbo for example, have you heard of VAG-com (or it's modern equivalent!) which allows you (by way of a laptop) to scan the vehicle for fault codes?

If the glow plug lamp is flashing then the vehicle has detected a fault and the stored codes should give you a place to start looking. Otherwise you'll have to pay the garage to do this for you.

There are several articles in the reference library regarding home diagnostics with VAG-com, look at the second section down here.

[GrahamW]

Thank you Paul. I shall look through the info on the link to find out more about CAG-com. I have ordered some vacuum tubing off the internet and will replace some of the hoses - there are various scuffs and weak looking bits that may be hiding cracks. It is getting old!

[GrahamW]

I have had the codes read - there were 2 instances of code 542, Stroke Sensor Nozzle Needle, and one for the engine speed sensor (intermittent).
Any one know what a stroke sensor nozzle needle is?
Last night the car refused to start for a long time, then when it did it was fine until it has the misfire/split second power cut again. Could this be a relay mucking stuff up - my Haynes Manual says relay 209 is the Diesel power supply relay and the wiring diag shows this affects the injector starting solenoid. Would this explain a misfire too?
Thanks guys,
Graham

PS I have seen mention of a relay 109 - is this the same relay as a 209?

[insanitybeard]

The needle lift sensor is usually incorporated into injector number 3 for ignition timing purposes, it's possible the sensor has become worn with age & use, if so I believe the whole injector may require replacement- there's a little more about in in section 3 of this article, though I'm not exactly sure how the system is impemented on the Mk1 Gal.

I'm not that familiar with the older type mechanical fuel pump systems but I'd say a dodgy needle sensor could be causing your problem.

If Haynes are referring to relay 209 as a power supply, then it could be a typo on their part. It's not one I've come across anyway!

[GrahamW]

Well I have found that one of the wires from this lift sensor is frayed just beyond the connector away from the injector - when the rain stops I'll solder some replacement wires in and see what that does.

[GrahamW]

All is well - now done a few hundred miles on it with no more problems. Power loss and misfires due to frayed wire from needle lift sensing valve on injector.