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Author Topic: Warranty Repairs - Turbo, Coolant Leak, Engine Wiring Harness (not covered-£350)  (Read 7524 times)

Offline DDM

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Re: Warranty Repairs - Turbo, Coolant Leak, Scratched My Leather Wheel!
« Reply #15 on: April 12, 2014, 12:35:21 am »
how many miles are you doing roughly in them 3 to 4 weeks?

Offline MikLSP

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Re: Warranty Repairs - Turbo, Coolant Leak, Scratched My Leather Wheel!
« Reply #16 on: April 12, 2014, 12:39:17 am »
Well it's varying quite a bit now since the Mrs started her maternity but probably anything from 100-500 a week.
The most regular use at the minute is short trips to the shops or nursery.

Offline MJ

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Re: Warranty Repairs - Turbo, Coolant Leak, Scratched My Leather Wheel!
« Reply #17 on: April 12, 2014, 12:42:00 am »
Plugs on a 16v are a bit of a bugger to pop out.

Egr cooler is not one to rule out and can be removed and tested.

A chemical block test is also a good way of indicating an internal leak but relies on exhaust gas to coolant contact and this often isn't the case.
2005 VW Bora TDI 130 Highline auto. Current mods: 5.5lt washer bottle & black and aluminium A/C knobs & 312mm front brakes and 256mm vented rear brakes.
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Offline MikLSP

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Re: Warranty Repairs - Turbo, Coolant Leak, Scratched My Leather Wheel!
« Reply #18 on: April 16, 2014, 07:55:46 pm »
Well, it seems there will be more for VW to investigate now as I just got this warning as I was nearly home today:


I've not tried my old VAGCOM cable to check for faults yet but it's a cheap blue ebay job so I doubt it will work. Has anyone had this and what was the cause? Some searching suggests sensors or wiring but I wonder if it may be related to the turbo flaws VW already identified. Naturally I will be ringing them in the morning and hopefully it will be safe to drive 20 miles to get it to them but Easter weekend is one hell of an inconvenient time for it to happen.

Offline xjay1337

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Re: Warranty Repairs - Turbo, Coolant Leak, Scratched My Leather Wheel!
« Reply #19 on: April 22, 2014, 09:43:58 am »
That's a glow plug light.

Offline MikLSP

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Re: Warranty Repairs - Turbo, Coolant Leak, Scratched My Leather Wheel!
« Reply #20 on: April 22, 2014, 10:58:11 am »
Yes, it is the glow plug light but it is also used as a general engine management warning lamp on the diesels.
Apparently it can appear amber or red and can be just lit or flashing.

My old VAG-COM cable managed to find two fault codes which were for boost pressure sensor and inlet air temperature sensor. It's going in tomorrow so hopefully all will be resolved.

Offline MikLSP

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So today I spent all day wandering around Preston waiting for VW to diagnose the engine fault and by 17:30 they finally had an answer. The problem is a broken wire, or wires, within the engine wiring harness and I have been advised that the whole thing should be replaced. Unfortunately, wiring is considered a perishable item and is not covered under my "All Component Warranty " so I'm looking at ~£350 to get that done. Has anyone had similar work done with our without warranty and does that cost seem fair?

Also was there a recall on the wiring harness or just the injectors, they have been done btw.

The car obviously need to go back in again and this time they have requested it for at least a couple of days, partly to get the wiring done but also because VW are requesting further evidence on the turbo including detailed photographs of the wear in question. The engineer informed me that he doesn't doubt the turbo needs replacing and that the siren noise is caused by movement in the balance bar, whether directly or by consequence I'm not actually sure, but VW want to be sure I guess so it has to be done.

Offline MikLSP

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Anyone had any experience with the engine wiring harness at all?

Offline Degudodger

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I would complain to VW Customer services as you might get a contribution.

Remember, Sale of goods act is the overriding factor   :smiley:
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Offline MJ

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Anyone had any experience with the engine wiring harness at all?

Yeah, quite a common fault on the BMN engine. The harness is not properly shielded from the heat in the engine bay so it causes the map sensor reading to go ape sh*t, hence the 2 map related faults.

A new, more robust harness is fitted to counteract the heat soak and prevent further issues.

It's a pig of a job as the ecu harness plug needs striping to replace the faulty wires and the new loom routing.
2005 VW Bora TDI 130 Highline auto. Current mods: 5.5lt washer bottle & black and aluminium A/C knobs & 312mm front brakes and 256mm vented rear brakes.
Next: turborevs SMIC, 20vt pancake pipe and silicone connectors.

VCDS, ODIS, VAS - PC and multi brand diagnostics around Manchester - pm me for help and advice

Offline MikLSP

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Thanks for the replies.
The faults are constant, not just when the engine is hot but I guess constant heat cycling would lead to damage in the wires.
They did say it would be an awkward job and reckoned about 5 hours.

I don't know whether customer services would be willing to help out as wiring is specifically listed as something that is not covered but there's never any harm in asking, especially if it is a common problem which has led to an updated part as a replacement.
« Last Edit: April 28, 2014, 08:36:29 pm by MikLSP »

Offline Degudodger

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Have you had the injector and wiring loom recall done?
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Offline MikLSP

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Yes, that was done before I bought it but I have all the documents.

Offline Degudodger

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VW parts carry a 2 year warranty. When was it done?
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Offline MikLSP

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Yeah, I thought of that. January 2012 :-(

Isn't the recall just in the injector wiring though? I assumed the wiring loom in question now was different anyway.