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Bora TDI PD115 "juddering"


Tristan177
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Good evening ladies, gents...

i have been experiencing e wierd phenomenon since about a month now, my wonderful Bora shakes!!! it started after stopping at a roundabout to let the cars flow, i have since then changed pistons, rings, big end bearings and of course cyl-gasket but the issue is still there, has anyone had this problem? is it related to injector cables or even worse, the injectors themselves?or injection quantity?

the car runs just the same with Upsolute chip as with the original, no other signs of trouble, EGR bypass has been tried... i'm out of ideas...can anyone help please...?

it just rune like it's on 3 1/2 cylinders..

cheers

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It does sound like the injector loom inside the head. There's a regular problem which some folk on here have experienced with cylinder number 1 misfiring, and it's caused by the connector to the injector. It's not expensive for the new connector, and I'd be tempted to try that first.

Have you had the car scanned for fault codes? That would be a starting point aswell. 169144-ok.gif

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Hi Rustynuts, after long looking at the forum here, you are "THE "guy to chat to....my first orientation was the damn cables and my local dealer said it could be that.. I will follow advice and get car put on 1551 for check, otherwise it doesn't seem to run too bad when under slight load, it can be felt most at tickover and under "harsh acceleration" with or without chip...

for the moment, to get rid of the 'orrible black cloud, the chip is back in it's box, but honnestly doen't change a lot to juddering..

quick explain: i bought thhis car as a 2nd hand in nov 2006, did less than 1000km's with it and had to change turbo, the diesel "specialist" said engine was shot due to amount of sump pressure, i'm now back at work after a 3-day strip-down and change of pistons, rings,gasket and big end bearings... these have solved the crankcase pressure however..it appeard the previous owner did some wooshy work and "SANDED?!?!?!?" the pistons to clean them.... can you believe people are so daft? they had around 1.2mm of lateral movement in the bores...

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Oh, I've heard of someone taking out their injectors to clean the carbon off them, and putting them on a wire wheel on a bench grinder to clean them. crazy.gif You only do that once aswell....

Sounds to me like you've got a bit of a job on sorting this out after the previous owner tried and failed.

If you have a search on here for a post by Wobby, you'll find that he had the injector harness problem, although his was on a Passat. It'll maybe give you a bit more of an idea what it was like when it was misbehaving. 169144-ok.gif

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Hi Rustynuts, gooo-moaning... ;-)

i tried a quick search for "Wobby's" article but cannot find it so will have to wait for rdv with local dealer (who can actually be called a dealer, he is actually honnest & helpful)

damn difficult engine to do though, we've got 12 VW's in the family of which only one is now a 1.9TD, all the rest are tdi technology.

for the guys out there wanting to change timing belt all on their little own, you'll spend more time fighting with the hydraulic belt tensionner than anything else, but after getting annoyed with it it does eventually go on..

PS: don't forget that when belt needs changing on AJM type engine, change also the tensionner wheel and water pump.

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When mine went it had a slight misfire that immediately made me think it would be the loom in the head (thats because of reading the posts and help from this great forum!)

After 2 days of a slight misfire it turned into a 3 cylinder only engine smile.gif . With a diesel i think that feels much worse than a petrol running on 3. It was awkward on the Passat because the bulkhead was in the way, not sure it will be on yours? It took me 2 hours but i do mess about and take my time.

Hope you get it sorted 169144-ok.gif . Also hope you didn't pay too much for the car, it sounds a nightmare.

I will have the VAG COM log somewhere for the injector loom fault but TBH it only shows up as an intermittent injector fault.

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Thanx Wobby, i went to local garage and i'll have the part tomorrow for +/- 50euros... the guy even talked about giving me an engine (one that had been replaced under guarantee)... might be on a winner here...i'll have all the necessary parts anyway...

on transverse engine, nothing is really in the way, just whip out the two clips and slide out cables.

i hope i can be of some help to anyone on this site as i do have great knowledge of diesels, i just don't understand...the guys here in belgium just stare at me and say "you did that yourself?" i mean every brit knows about cars, don't they? lol

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i was hoping so but then again...

it's just too easy going down to auto5 (french/belgian version of halfords) and buying an exchange engine and slapping it in, no one here (belgium)seems to know anything about mechanics, they are all too keen to "chip" the cars, but when they get a problem, dial-a-garage.....

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HI folks, been to VW for full diag, result ===> nothing wrong electronically with the car, runs on all 4 cylinders with no misfiring at all... some chirpy guy in the garage mentioned "oh, sound like the dual-mass flywheel/clutch assembly out of balance" now he could be right as a "horrible" noise like a nut being ground away did pop up 3 weeks before juddering started, the noise only lasted 2 seconds, even though diag shows that engine is now healthy, it still could be injector-nozzles, the core and solenoid operate correctly but that means pfff for the nozzles giving right pattern.

1st things 1st==> will lump off gearbox asap as i want to change the thrust bearing, i will take the opportunity to check whole mechanism and keep you posted.

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  • 3 weeks later...
  • 2 months later...

pump-injector units replaced at last, problem is still there, still got to change release bearing, will do so thursday with brother's help, the smoke/power/judder issue must be due to bad setup of the timing belt, i can't see anything else it can be, pre-injection make the car judder..

pffffff.... wife's polo runs smoother than my car

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  • 2 weeks later...

Hi Folks, car is sorted out, it was due to the bearing between the dual-mass and the flywheel, it had flown to pieces thus wrecking the whole clutch assembly, so i have changed a lot of this for nothing, doesn't matter as i am keeping the car, at least i have something i can rely on

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  • 2 years later...

Hi all this is my first post! I have a bora 115 pd ajm 2001 and it is misfiring at idle and at speed. vag com says misfire cylinder 1 - So I took the cam cover off to discover I had a broken plunger on top of the injector, assuming this was the cause of the misfire and juddering, i replaced the plunger, i also cleaned the injector loom connections!

Put it all back together and the same problem continues and the vag com instantly records a misfire.

My question is do i need an injector loom ????? or what do i check next???:ffs: your opinions/experiences would be appreciated.+++

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