Pure magnetism

Presented with a golf 2.0 suffering with a stalling problem didn’t suggest a particular challenge to cost or process however this did turn interesting for many reasons. The pumpe duce 2.0 diesel is no stranger to our workshop. Having expanded and developed our business through internet marketing and specific product focus, we have, despite the recession attracted a quqlity conscious clientele.

This resurgence of interest has also passed through to our regional training, especially with common rail, dpf, and oscilloscope training, this topic closely mirrors the processes and techniques from our training program. In reality it’s our unique commercial knowledge that passes through to our training.

Much of our success is due to the way we advise and control the repair process. This begins with listening to the customer, then advising of procedure and cost. Reporting back accurately with a concise and durable repair strategy. Based on cost not price.

Price is based on the lowest common denominator, or how cheap someone is prepared to drop, using parts that don’t match original build specification, and sadly compromising on labor value.

Cost is the true value for every job, its value is often obscured by many things. Time, tools, parts, training, and even things like environmental costs in simply running your business.

With these assumptions in mind, let’s take a look at the golf.

The owner, like many these days can be quite knowledgeable, or misguided by popular opinion often referred to as the internet! Ours was the former, previous attention had revealed no dtc errors, although this does not disqualify the possibility if a sensor or circuit value error, it does by implication demand a different approach and cost!

A new egr valve had been fitted, however the symptoms of poor starting from cold and stalling were often present.

I began with a global vehicle scan using autologic, no just seeking a dtc but looking for sensor value deviation or correction, without success. I decided to conduct an intake integrity check, using our modified smoke pro, even under an increased pressure no evidence suggesting an internal or external leak existed. I then conducted a dynamic road test using autologic and a pressure gauge to monitor turbo boost, noting request, specified and actual values, all of which matched perfectly. Returning to the workshop to consider my next move I noted, a reluctance for the engine to start.

The possibilities are endless as to cause, so I decided to monitor the crank and cam sensors (triggering) via the serial port. To enable a stable environment power support was provided to both autologic and the vehicle battery using fronius. However, and despite this communication with the pcm dropped out every time the vehicle was cranked.

There was no option but to access the pcm and conduct further pin out testing using Pico scope.

What happened next was both interesting as well as surprising, having accessed the crank and cam sensor outputs it clearly identified a clear but intermittent partial output failure. Made even more curious by the fact that no misfire or unevenness of the engine was present. PICO IMAGE

Due to the mathematical predictability of the error it could not be due to a wiring or sensor failure, such is the advantage of oscilloscope analysis. Reporting back to the customer with the really bad news, it’s a gearbox out job to replace the phonic wheel. This rather fragile magnetic disc requires precise positioning on the crankshaft using a special locking and fitting tool.

With the gearbox out, further assessment confirmed the need for a new flywheel and clutch. With all the chickens in the hut an accurate final cost could be confirmed. The original Sachs dual mass flywheel and clutch was replaced with a superior luk part set. Luk invented and retain production copy right. Sachs produce there variant on the patient under license.

The gear box was steam cleaned and the concentric release bearing primed prior to reassembly.

The conclusion to a very satisfying professional job, and a very satisfied customer, as for the car it was being sold the very next day! Such was the confidence and agreement between the repairer and owner. I hope this tale highlights the true meaning of cost, and the need for training and investment delivered by craftsmen.