The TDi is dead... time to resurrect the ZHP

In the spirit of another thread I just read through, I figured I would start one of my own to keep me honest... Consider yourselves my accountability group :conversation lol.

Been driving my 6 speed TDi Jetta wagon for a while and timing belt let go about 50k miles early on the highway. Wanted to fix it but there are so many little things wrong on a car that has 270k miles and was only probably worth 2500 before it broke. So in process of getting that car gone, and had to debate on getting something new or putting the ZHP back on the road. Was originally going to sell it but didn't have the money to fix the power steering failure so car sat for about a year. When the VW died decided to keep this and make it nice again, will probably end up getting something next year but for now will enjoy the E46.

Car was down for power steering failure and just paid a local shop with a BMW mastertech to fix that and diagnose other items on the car. They replaced the pump, as well as the high pressure line and the car is now happily back on the road. They also found a vacuum leak around the DISA so I added that to the below list.

Work Done:

• Power steering pump and high pressure line, power steering fluid flush
• Oil Change with German Castrol 0W-40 and Purolator Pure One filter
• Quick Clay and Wax
• New Battery
• New ZHP shift knob

Future Mechanical Work:

• DISA Valve -DONE
• Ignition Service kit with coil packs and plugs - DONE
• Dinan Air Filter - DONE
• MAF - DONE
• Upper Intake Boot - DONE
• Upstream and Downstream 02 Sensors - DONE
• Intake/Exhaust Cam Position Sensors - PARTS IN HAND
• FCP Euro Brake Kit
• New Shoes
• Belt, Pulley, Tensioner kit from FCP Euro
• New Filter for Cabin
• Replace PCV System
• Motor Mounts
• Transmission Mounts
• Subframe and suspension Bushings
• UUC Shifter Rebuild/Replacement

Future Cosmetic Work:

• New Matte Black Kidney grills - ORDERED
• New headlight lenses - ORDERED
• Euro Clear Corners - ORDERED
• Clear Side markers - ORDERED
• OEM Grill
• ZKW Fog lights and Bezels
• LightWerkz headlight update (in the future)
• Euro Tail lights (not sure who makes the best quality)
• Paint Correction
• New Dinan Emblem
• Headliner and pilars redone
• Interior LED lighting update
• Leather steering wheel (currently have dead alcantera)
• Windshield Replacement
• New Side Mirror Reflectors

Welcome back.

Good plan, man. How many miles on the zhp ?

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Originally Posted by fredo

Good plan, man. How many miles on the zhp ?

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150k even


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Do you guys have any recommendations on "must have" E46 tools? I know that I need some Torx, some allan sockets and such for ease of installtions. I know for my MR2's it was basically 8mm, 10mm, 12mm, 14mm 17mm and you basically had all the sockets you would ever need.

There are some good sales on Sear stuff right now like a 42 piece allan, torx, reverse torx, philliips and flathead socket set for like 25, but if I'm never going to use the stuff.... may not be worth it when I kinda want a new 84 tooth ratchet.

Work complete for this weekend:

- Replaced DISA
- New Plugs and Coilpacks
- installed new ZHP shifter
- did some detailed cleaning on the engine and engine bay and a quick spray wax and tire dressing for good measure




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While you're in the engine bay, I'd recommend replacing the torx bolts with standard 8mm or 10mm bolts. A few of us have been doing that to make life easier down the line.

Matching the threading is pretty simple and it's made my weekend maintenance over time that much easier.

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I actually kinda did the opposite. There was a deal on 3/8” drive hex, torx, reverse torx, and bits for like 25 from craftsman, so bought that instead lol has most of what I needed


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Sorry about your TD-Lie. I’m now driving a 2015 Golf TDI with 123k on the clock. I do miss the zhp.

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Originally Posted by Xceler8

I actually kinda did the opposite. There was a deal on 3/8” drive hex, torx, reverse torx, and bits for like 25 from craftsman, so bought that instead lol has most of what I needed


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If it works, it works haha.

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Originally Posted by ELCID86

Sorry about your TD-Lie. I’m now driving a 2015 Golf TDI with 123k on the clock. I do miss the zhp.

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How reliable has it been. May replace mine with a 2015 Golf Wagon in a few months. Wasn’t sure about emissions issues from an engine code perspective. Not really worried about the emissions


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Quote:

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Originally Posted by Xceler8

How reliable has it been. May replace mine with a 2015 Golf Wagon in a few months. Wasn’t sure about emissions issues from an engine code perspective. Not really worried about the emissions


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So far so good. Timing belt needs to be done at @120k and requires some special tools. I found a local Indy to do mine. I have DSG and the fluid is every 40k. Oil is 10k.
Not a bad little car (but not that fun to drive [emoji20]). Mine is under the recall extended warranty so I’ve not done a tube or anything.

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Originally Posted by ELCID86

So far so good. Timing belt needs to be done at @120k and requires some special tools. I found a local Indy to do mine. I have DSG and the fluid is every 40k. Oil is 10k.
Not a bad little car (but not that fun to drive [emoji20]). Mine is under the recall extended warranty so I’ve not done a tube or anything.

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I'm on same boat as you, I'm driving a 2015 Golf TDI as well. I've been itching to get the KermaTDI tune to make the car more interesting but I don't want to void the warranty.

Blackstone Labs recommended me to change the oil every 15,000 miles based on the test results. I commute about 100 miles per day on the highway.

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Originally Posted by FungShui

I'm on same boat as you, I'm driving a 2015 Golf TDI as well. I've been itching to get the KermaTDI tune to make the car more interesting but I don't want to void the warranty.

Blackstone Labs recommended me to change the oil every 15,000 miles based on the test results. I commute about 100 miles per day on the highway.

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I just got my first blackstone report back today. They recommend I go 12k on the next oil.

Attachment 35874

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Originally Posted by FungShui

I'm on same boat as you, I'm driving a 2015 Golf TDI as well. I've been itching to get the KermaTDI tune to make the car more interesting but I don't want to void the warranty.

Blackstone Labs recommended me to change the oil every 15,000 miles based on the test results. I commute about 100 miles per day on the highway.

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My 2003 had a Kerma tune, their full three inch turbo back, and a gli 6 speed in it... the car wave so much fun for what it was, and made all the right noises


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So did the disa and ignition system work and car ran great for a few days... but its back to being a dog; not sure but I suspect a fuel system issue.

Anyone know about the reliability of the fuel pumps in this car... tempted to just add fuel system rework to the list of mechanical parts that need to be changed.

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Originally Posted by Xceler8

So did the disa and ignition system work and car ran great for a few days... but its back to being a dog; not sure but I suspect a fuel system issue.

Anyone know about the reliability of the fuel pumps in this car... tempted to just add fuel system rework to the list of mechanical parts that need to be changed.

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Disconect the maf sensor and see if the car runs any better.

Also the fuel filter is a preventative maintenance item.

Just to add to what Vas said, going beyond 150k miles on a fuel pump isn’t advisable...


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Originally Posted by san

Just to add to what Vas said, going beyond 150k miles on a fuel pump isn’t advisable...


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He said fuel filter, so which one are we talking about. I only have about 20k on the filter.


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Quote:

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Originally Posted by Vas

Disconect the maf sensor and see if the car runs any better.

Also the fuel filter is a preventative maintenance item.

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Also went ahead and disconnected the MAF, car ran smoother and seemed to have a bit more torque downlow. Not sure what that means in this case


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Quote:

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Originally Posted by Xceler8

He said fuel filter, so which one are we talking about. I only have about 20k on the filter.


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Both the pump and filter are preventive maintenance items. I was talking about fuel pump.


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Quote:

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Originally Posted by Xceler8

Also went ahead and disconnected the MAF, car ran smoother and seemed to have a bit more torque downlow. Not sure what that means in this case


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Gotcha. I thought the fuel filter was never replaced.

As far as the maf, when it's disconnected and the car runs better, the maf actually has a soft fail. The ECU defaults to a base map with it unplugged ( car will run rich )

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So found a really good BMW specialist here and what we found after rechecking is that there are no vacuum leaks with a high degree of certainty.

We did find that the fuel correction value in the ECU was stuck at 12%. He said this should change based on O2 signals and MAF readings and RPM. Wasn’t moving even with MAF disconnected. He actually said MAF was reading correctly.

I had the shark injector tune on the car so I reverted back to stock and saw the same thing. The value is an internal tune value so not sure why it’s stuck.

I’m planning on taking it to have the ECU reflashed to factory and then have the dinan stage 3 put on it as they should be able to do both at the same price and see what we have.




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Quote:

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Originally Posted by Xceler8

So found a really good BMW specialist here and what we found after rechecking is that there are no vacuum leaks with a high degree of certainty.

We did find that the fuel correction value in the ECU was stuck at 12%. He said this should change based on O2 signals and MAF readings and RPM. Wasn’t moving even with MAF disconnected. He actually said MAF was reading correctly.

I had the shark injector tune on the car so I reverted back to stock and saw the same thing. The value is an internal tune value so not sure why it’s stuck.

I’m planning on taking it to have the ECU reflashed to factory and then have the dinan stage 3 put on it as they should be able to do both at the same price and see what we have.




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12% was short term or long term fuel trims?



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I don’t remember, but from what he was telling me that should have been moving around with throttle input and when he was spraying some brake cleaner into the pcv system when we were looking for vacuum leaks. And it never changed.

The only concern I have is an issue in the ecu caused by the shark injector tuner since basically the whole manual is a warning about damaging your ECU.

My plan is to take it to a dealership that can do a software update and install fresh on the car, and potentially put a Dinan stage 3 tune since it has throttle body, exhaust, and intake and check the trim value again.

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Your mechanic should have noted the short/long term fuel trims at idle and at 2500. If the numbers dropped down when the engine rpm was increased, it would point to a vacuum leak. If the numbers did not change, the you are either looking at pre-cat o2 sensors, maf sensor or a fuel related issue ( fuel filter or fuel pump )

Spraying brake cleaner is not the proper way to diagnose vacuum leaks on these cars. You need to use a smoke machine which would easily pin-point any small or big leaks.

However if the fuel trims were at 12% which are really high, I would look into points of entry after the maf sensor like the disa o-ring or the throttle body boots. You can remove the disa and see if the o-ring is seated properly or inspect the throttle body boots for any tears. But you also mentioned that the car ran better with the maf disconnected so cleaning it with some maf cleaner could yield some improvements.

So the DISA has been replaced and we are replacing all 4 of the O2 sensors. I’m also going to go ahead and order the boots so I have those done too.

We were going to recheck the O2 sensor function and the fuel trim again. I have the fuel pump and filter on the list for next months car budget.


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Pulllling this one back up. So I get the car back from paint today, and going to get back to work. Just a quick update on whats been done and whats getting done.

Work Completed (updates in Bold):

• New Dinan Air Filter
• New MAF
• New Upper Intake Boot
• DISA Valve Replaced (New)
• New Plugs
• New Coil Packs
• New Upstream and Downstream O2 Sensors
  
• Reflash of ECU to stock at BMW
• Fuel Trims Noted prior to Reflash, will be getting them rechecked
• New Main Fuel Pump and Fuel Filter

Even after all this, car still has some weird low end hesitation and issues up top occasionally. Read a few places that Cam Position Sensors may cause issues with low end problems so this is what I have next:

• Intake and Exhaust Cam Position Sensors
• Lower Intake Boot (ordered)
• CCV System (although didn't seem to have any blockages when it was in the shop)

To continue the discussion on fuel trims... I don't know what the numbers mean in context but below is the print out I got from BMW. I plan on taking the car back in and having them pull the trims again since I've put some miles on the car since this measurement was taken and the ECU was reflashed:

• Adaptation, mixture, bank1, additive: 0.72 mg/Hub
• Adaptation, Mixture, Bank 2, additive: 0.44 mg/Hub
• Multiplicative bank 1, mixture adaptation: -8.00%
• Multiplicative bank 2, mixture adaptation: -8.00%

Nice werk

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