FSI - Lumpy idle and Cylinder misfires fixed!

Hi

I bought my FSI back in early September and she’s never felt quite right. I just thought I’d post what symptoms she had and what I did to resolve them; it’s nothing that is not mentioned elsewhere but I hope it may of be use to someone else to have them in one place.

So, from day one there was hesitation whilst setting off from a stop (at junctions etc), sometimes to the point where she felt like she was going to stall when the clutch began to bite, and I had to de-clutch and really give some revs to make it across the road at times. The solution was to replace the fuel tank breather valve. (That link is for exact one I purchased). Once fitted (5 min easy job) she felt much much better and the hesitation was pretty much gone - no more risk of death at junctions.

However, she still didn’t feel quite right, and felt flat at times at higher revs - but VCDS (unregistered lite version) showed no codes, apart from intermittent oxygen lambda.

After a few weeks, not a huge amount of miles, the EML came on whilst I was driving back from my dads house and I thought she was losing fuel. What I thought was fuel loss turned out to be a transient glitch with the fuel gauge (it’s been fine since) but the EML light was due to codes 16684 and 16685, being multiple cylinder misfire and a misfire detected on Cylinder 1.

This morning, I set out to diagnose the cause. First, I checked the earth cable (the one behind the passenger headlight). It looked fine but I removed it, cleaned the mating faces anyway and refitted. She hadn’t been started for a couple of weeks, so was very cold and the idle was lumpy. I then checked the connection to the camshaft sensor (right hand side, top of the engine block) and to the naked eye it seemed absolutely fine, so I put it back. I also unscrewed the sensor itself and looked inside the block - nothing untoward - so I refitted. So, on to the cylinder misfires. VCDS said cyl 1 was misfiring so I swapped over the ignition coils of cylinders 1 and 3, cleared the VCDS codes and then started her up and waited for the EML to come on again - which it duly did after some gentle revving. She was still idling lumpy and there was some popping at the exhaust but this time VCDS reported a misfire on cylinder 3, instead of 1, which indicated that the coil pack that had been in cyclinder 1 (but was now in cylinder 3) was very likely duff. Three of the coil packs seemed to be the original vag parts and one was a Delphi. Not wanting to replace just one, I duly purchased 4 new Bosch coil packs and also decided to fit new Denso spark plugs at the same time (see photos for specific part numbers). This cost me circa £170 but it was worth it, as once fitted the transformation was amazing. Perfect idle, no hesitation, free revving and feels great. Even my wife said she sounded good when I drove off for a test drive.

So, for the moment (fingers crossed) I have an FSI that is pretty much everything I wanted her to be.

The whole job of replacing all 4 coils and spark plugs took about 20 minutes. It was a bit fiddly getting the actual coil packs out - gentle levering with a wide blade screwdriver - and then those bloody notched VAG cable connectors that you need to gently lever away, but other than that it was easy. Just to be clear, I’m not a car mechanic, just a DIYer.

I hope this write-up is of use to someone.

Nb. I’m keeping the Delphi ignition coil that I removed as a spare, as it looks fairly new!
 

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Hi

I bought my FSI back in early September and she’s never felt quite right. I just thought I’d post what symptoms she had and what I did to resolve them; it’s nothing that is not mentioned elsewhere but I hope it may of be use to someone else to have them in one place.

So, from day one there was hesitation whilst setting off from a stop (at junctions etc), sometimes to the point where she felt like she was going to stall when the clutch began to bite, and I had to de-clutch and really give some revs to make it across the road at times. The solution was to replace the fuel tank breather valve. (That link is for exact one I purchased). Once fitted (5 min easy job) she felt much much better and the hesitation was pretty much gone - no more risk of death at junctions.

However, she still didn’t feel quite right, and felt flat at times at higher revs - but VCDS (unregistered lite version) showed no codes, apart from intermittent oxygen lambda.

After a few weeks, not a huge amount of miles, the EML came on whilst I was driving back from my dads house and I thought she was losing fuel. What I thought was fuel loss turned out to be a transient glitch with the fuel gauge (it’s been fine since) but the EML light was due to codes 16684 and 16685, being multiple cylinder misfire and a misfire detected on Cylinder 1.

This morning, I set out to diagnose the cause. First, I checked the earth cable (the one behind the passenger headlight). It looked fine but I removed it, cleaned the mating faces anyway and refitted. She hadn’t been started for a couple of weeks, so was very cold and the idle was lumpy. I then checked the connection to the camshaft sensor (right hand side, top of the engine block) and to the naked eye it seemed absolutely fine, so I put it back. I also unscrewed the sensor itself and looked inside the block - nothing untoward - so I refitted. So, on to the cylinder misfires. VCDS said cyl 1 was misfiring so I swapped over the ignition coils of cylinders 1 and 3, cleared the VCDS codes and then started her up and waited for the EML to come on again - which it duly did after some gentle revving. She was still idling lumpy and there was some popping at the exhaust but this time VCDS reported a misfire on cylinder 3, instead of 1, which indicated that the coil pack that had been in cyclinder 1 (but was now in cylinder 3) was very likely duff. Three of the coil packs seemed to be the original vag parts and one was a Delphi. Not wanting to replace just one, I duly purchased 4 new Bosch coil packs and also decided to fit new Denso spark plugs at the same time (see photos for specific part numbers). This cost me circa £170 but it was worth it, as once fitted the transformation was amazing. Perfect idle, no hesitation, free revving and feels great. Even my wife said she sounded good when I drove off for a test drive.

So, for the moment (fingers crossed) I have an FSI that is pretty much everything I wanted her to be.

The whole job of replacing all 4 coils and spark plugs took about 20 minutes. It was a bit fiddly getting the actual coil packs out - gentle levering with a wide blade screwdriver - and then those bloody notched VAG cable connectors that you need to gently lever away, but other than that it was easy. Just to be clear, I’m not a car mechanic, just a DIYer.

I hope this write-up is of use to someone.

Nb. I’m keeping the Delphi ignition coil that I removed as a spare, as it looks fairly new!
When they are good, they are very very good, these FSIs!
Well done for keeping the faith.
Mac.
 
Have you thought about a proboost ECU for increasing the simplicity of the system and therefore reducing the likelihood of future problems? If it were me I’d do this now while everything is working as it should.
 
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