Galaxy, Sharan, Alhambra Intermittent Starting Problem

[matty]

I just wanted to share a fault I found and solved on my Sharan 115 bhp 1.9 tdi. 2002.
Sometimes, if making short journeys I would stop at the fuel station for example and then be unable to start it again without lots of trying and eventually it would fire and run fine.  The car ran normally apart from very slight hesitation when cutting revs and then accelerating sometimes.  I found it was a simply the EGR valve sooted up in thick gunk, jamming the valve shut and not allowing any air through.  It's removed by removing the air cleaner box and the connected pipes (It's at the back of the engine on the right side.) and with an allen key it has 3 bolts.  Clean it in car cleaner or petrol and then refit it.   

[brummygit]

I think I may have the same problem - can you help me diagnose?

My 55 plate TDi 150 has suffered very much as you say. It always cranks quickly (battery is new) but just occasionally it takes ages to start - usually it fires and runs in less than a second. I'd started to realise that it is never from cold, only when its done a short journey. Once running I would say there is no problem, but your comment on the hesitation is right and a couple of times it's been easily stalled.

I already have the car in part at the moment as the O/S headlamp leveller motor has failed so it's an ideal time to remove the airbox and clean the EGR - but the main problem is I haven't a clue what to look for. Can you give me some more information?

Thanks

[Chrispb]

  brummygit

Can you confirm what the led on the door is doing when the engine doesn't start also can you hear the fuel squelch noise from under the car when just turning on the ignition.

A 150 eh not many of those about!!!!

[brummygit]

Thanks for your reply.

The door LED is normal (on for a second or two then off) and I've not noticed any difference in the noises when the ignition is turned on.

I had been thinking relay 109 but LED and no major bad running or cutting out seems to discount that.

Mileage on the car is 93k and it blew a turbo in big style last Christmas so the EGR is quite likely to need a clean by the sound of it.

[brummygit]

A 150 eh not many of those about!!!!

Yes, we bought it new - it goes nicely but eats tyres. I'm not too sure just how much quicker it is over a 130, but it's done the long haul to the South of France quite a few times and will eat the miles even with 5 on board and the boot loaded to the roof. It's been a great car but is starting to need a lot of TLC now

[Chrispb]

Agree cleaning the manifold and EGR can only help with performance and boost issues but don't think it will help with intermittent starting problems.

Have you got your own lead + VCDS lite software for checking diagnostics yourself, as you may have some codes stored that could help with the problem

[brummygit]

Thanks

I just took a look at the EGR and the lower body is covered in black oil - I assume that's not good 

Unfortunately I don't have VCDS although I've thought about buying many times. I currently have a non-functional booster heater and my local VW "specialist" is better with spanners than computers so I've drawn a blank there.

I've thought about buying - do you know if the lite version could reset the fault codes for my booster heater if it's locked itself out? Also where is the cheapest place to buy the full version - it seems to be a minefield of different versions and interfaces from my quick look around.

I'm too far from Kent to be able to visit you, but the other alternative is to find a member nearer to me in the West Midlands.

[Chrispb]

The EGR's tend to leak oil when the valve spindle gets worn, but providing valves working ok will not affect the running just cause a mess.

Here is a link to the cable you need and where to get the free software.
It's not essential to have the full version as most things the average diyer need are free

http://www.ebay.co.uk/itm/VAG-GROUP-USB-OBD2-II-KKL-ECU-DIAGNOSTIC-CABLE-LEAD-Compatible-VCDS-LITE-or-409-/330753371108?pt=UK_Diagnostic_Tools_Equipment&hash=item4d026febe4

http://www.ross-tech.com/vcds-lite/download/index.html

The booster heater on the later MK2's have the D5WZ-F unit  seems prone to controller failure within the unit.. usually giving a dosing pump short or similar

You will need to scan each module individually as you can't do autoscan with the unregistered version.

Any problems getting started with VCDS lite then ask on here, there's also more info on the Ross-Tech site

[brummygit]

Thanks  , I've ordered one of those cables and we can see where we go from there.

[brummygit]

Whilst twiddling my thumbs waiting for the diagnostic cable, and more importantly a headlamp levelling motor which has caused the car to be off road (dazzling Xenons, but that's another story), I decided to pull the EGR valve off anyway.

What a mess - I'm not a mechanic, but I'm shocked if it was working at all.

I't been soaked in petrol, gunk and EGR valve cleaning spray and is now mostly clear. The important parts are clean and the the flap (venturi?) inline moves nicely, but I notice that the valve from the exhaust is very hard to open. It snaps back shut like an angry aligator so am I right assuming that it just has a big spring behind it? If so it must take an awful lot of vacuum to operate the valve.

Next job is to refit it without dropping any bolts - that could be a tough one.

[Mirez]

Yup, one giant ass spring which is indeed impressive for a vac system to open!

A 150 with Xenon's eh? A super rare beast, still after one myself but the only one's I ever see are silver!

[brummygit]

Mine is Titanium so nearly as bad as silver.

I bought it new and spec'ed it up - put the Technology Pack on it, leather, baby seats, load cover & net but regrettably cancelled the 17-inch wheels after order due to fears of a very harsh ride. If I remember correctly the only option I didn't pick was the DVDs.

Its been a good car so far - for 7 years and 92,000 miles 

[brummygit]

So the Galaxy is back together and the intermittent starting remains after cleaning the EGR valve.

I'll start a new thread on this topic rather than further pollute the original post which has useful advice