Help with 2341 fault code

[andyg plym]

Following on from this thread :

http://www.s2forum.com/forum/showthread.php?t=74413&highlight=Wot

The Colgate wagon is running rough at present, pulled the codes and cannot seem to loose 2341.
Symptoms are poor cold start, starts fine then a few seconds after goes lumpy idling as low as 500 rpm and when you hit the gas it wants to cut out, I'd say it's running rich.
Once upto running temp it's better and although still lumpy idles ~850rpm.
Driving is a little jerky when changing gear but generally ok apart from being a bit hesitant at around 1.5 bar
Code relates to this;

-Fuel tank empty at least 10 litres
-Fuel system pressure too low
-Failure of spark plugs, ignition coils
and ignition output stages
-Ingress of air to G70
-Leak in exhaust system up to catalyst
-Faulty lambda probe
-Fuel system pressure too high

Plenty of fuel,year old 044 fitted
New plugs,1.8t coil conversion, although plugs checked since and black so cleaned
No exhaust leaks(found dp leaking but now sealed)
New Bosch lambda
New temp sensor on rear of head

Had a boost leak few weeks back repaired intercooler but haven't re-tested yet. Mfts connector was unplugged as broken but replacement now fitted

I find it odd how it improves once warm.

Any thoughts ? For me I'm going for possibly fpr, lambda no good,maf,fuel filter (been meaning to change for ages ) boost leak naturally

This all started one morning when I started it after going away for a week and we started getting cold weather.

Rs2 setup on ts chips

Thanks all, constructive feedback most great fully accepted !

[UrS4boy]

Another interpretation of the 2341 engine malfunction code

*2341 (Blink Fault Code), 00537 VAG1551/2 Fault Code Number

Oxygen Sensor Control Limit exceeded, fuel pressure too low or too high, intake or exhaust leak, defective ignition system component, intake air leak after air mass sensor, O2 sensor is faulty
Symptom: CO before catalyst is below 0.3% or greater than 1.0%, Extremely lean or overly rich exhaust, Spark Plug fouling

Over here, typically, we have found that this is the code that tells you that you have a boost leak.

Boost leak testing:

http://www.s2forum.com/forum/showthread.php?t=63974&highlight=boost+leak+testing

[newsh]

Have you tested the DV?

PCV leak, bad one-way valve?

[andyg plym]

Tested pcv system a few weeks back when leak testing and that's when I found a pin hole in the Ic , il try and do another test again tomorrow .
Dv is a forge 006 , seemed ok when I was swapping springs a while back , but do the forge ones fail ?

[newsh]

They can sometimes stick open, if you've got a 710n I'd swap it over to be sure.

The one way valve in the PCV, if it's not been replaced recently it will probably be leaking.

[andyg plym]

Replaced pcv valves a while back

[UrS4boy]

Replaced pcv valves a while back

And the boost leak testing results from today?

[bertman]

It has been said on here and I have found out from experience that the 006 can leak through the screw holes that join the two halves together.I found a leak on my 006 and used ptfe tape round the screws

[andyg plym]

Not today dave I will be testing tomorrow at work.

Makes you laugh , most issues as ever are boost leak related..
My friends all love my moto- "it's all about the boost !"

[andyg plym]

My mistake I've got a 007 !!

[andyg plym]

Update:
Boost leak tested but could only make 0.8 bar , air was leaking out of the oil filler cap.
Perhaps my breather system is clogged up. Did the soapy water spray on all hoses/ pipes but found no other leaks.

One thing I suspect though is a manifold leak, went up on the ramp and whilst underneath the downpipe are has an almost pinking sound, checked the manifold for cracks best I could but couldn't see anything. Downpipe joint to where the car would be has a small leak

On to the forge and I removed it to find slightly notchy movement so whilst out I thoroughly cleaned it with brake cleaner and lubed up with the only thing I could find which was injector paste ! Obviously made a difference as when I went for a drive it hit 1.9 bar for the first time although still hesitant.

You can actually drive through the hesitation to full boost.

I plan on cleaning pcv system as a matter of course and replace the oil cap but regarding the lumpy idle i don't want to admit it but I'm thinking it could be new manifold / downpipe time

Any one else have any bright ideas ?

[UrS4boy]

Any one else have any bright ideas ?

Yeh. Air should not becoming out of the cam cover at the oil filler cap.

Try the boost leak test again, except this time remove the hose/pipe that comes from the front of the ABY cam cover and enters the MAF to turbo hose. Block off both the MAF hose connection and the hose coming out of the front of the cam cover. Then do the test again. See what happens and report back.

I am talking about items 12 and 13 in this 3B/ABY/ADU PVC system diagram:

[andyg plym]

Will do when back at work later this week, my biggest concern is on cold start up, again I know we have discussed boost leak ls but could this issue be related ?
Good work on the diagrams dave btw

[UrS4boy]

AAN/ABY/ADU PCV system information

Good work on the diagrams dave btw

You're welcome. My suggestion re: Items 12 and 13 is really to focus in on the issue, i.e. if you still have pressure coming out of the oil filler cap during a pressure test, you either have a failed Item 20 one-way bleeder valve back flowing pressure through the Item 3 pressure regulating valve, through the Item 1A hose and into the cam cover where Item 8 is attached, OR you have leaking valve seals that are allowing pressure from the intake manifold into the underside of the cam cover. Neither is good.

Lots of AAN/ABY/ADU PCV system info here:

http://forums.quattroworld.com/s4s6/msgs/22506.phtml

[andyg plym]

Already replaced that part and rechecked the other day.