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Audi A4 B6 - Stuttering engine then stall - 2004 1.9 TDI - MarkHumphreys

Hi all,

I was very pleased to get an Audi as I have always wanted one and got this car recently as we dont have a lot of money. But then issues started to arise. Recent work done had been vacuum valve and crank sensor replaced.

First, discovered a flooded plenum chamber and water in relays under ECU which caused limp mode plus soaked carpets inside drivers and rear passenger behind driver side. Cleared blockage and dried out relays and all appeared good.

2 days later I got CEL light and code P0230 but car still ran fine.

3 days after this, as I was arriving home from a long drive on motorway the car started to stutter at about 10mph and then when I parked up and started it again, rpm was jumping up and down in idle and stalling, then it cranked but wouldn't start. I then replaced relay 219 under ECU as it appeared to have corrosion on the contacts. Cleaned electric contacts on relay holder. All other relays and fuses appear to be fine. Car took a little while to crank but once it did all appeared good again.

Drove for another 2 days with no issue, then today while driving, engine started to shudder and then stalled at 25mph losing power steering. Took about 3 minutes of cranking with foot on gas pedal to get engine started again. This happened 3 more times on way home but did make it back. No codes have come up at this point.

I have been advised to replace diesel fuel filter as first port of call but I'm worried I'm just going to be throwing money at it. Does anyone have any idea of the likely reasons behind this happening? I'm a novice mechanic i.e. brake pad and filter changes etc, I just hope someone has had the same symptoms and has been able to fix.

Thanks in advance all.

Audi A4 B6 - Stuttering engine then stall - 2004 1.9 TDI - Big John

Likely to be something to do with the flooded plenum chamber which can cause havoc. Are you sure you have sorted the drainage? The seal rots between the plenum chamber and the car interior and the brake servo can rust through due to the immersion in water - can even draw water through the vacuum pump.

Electrical contacts and components corrode all over the place so everything needs checking - I'd also remove the carpets to check everything electrical under there and properly dry out!

I doubt if it is the fuel filter. When the car was working not working what was the weather doing? - just a thought

Edited by Big John on 12/04/2019 at 22:31

Audi A4 B6 - Stuttering engine then stall - 2004 1.9 TDI - MarkHumphreys

Likely to be something to do with the flooded plenum chamber which can cause havoc. Are you sure you have sorted the drainage? The seal rots between the plenum chamber and the car interior and the brake servo can rust through due to the immersion in water - can even draw water through the vacuum pump.

Electrical contacts and components corrode all over the place so everything needs checking - I'd also remove the carpets to check everything electrical under there and properly dry out!

I doubt if it is the fuel filter. When the car was working not working what was the weather doing? - just a thought

Thanks for your reply. Weather wise, since I've drained the plenum chamber there hasn't been any rain to speak of so the weather has been either mild or quite warm for all of the significant stalling/engine issues. There is still moisture in the rear foot well that is noticeable when I push on the carpet but I've been so focused on getting the damn thing to drive that I've not really focused on that.

I will take your advice though and get is dry and check for any hidden electrics.

Audi A4 B6 - Stuttering engine then stall - 2004 1.9 TDI - dieselnut

Make sure you check under the front passenger carpet.

There is thick foam under the carpet which holds loads of water, then underneath all that is the CCU ECU which will be laying in water.

The plugs go green then wires start to fall off.

Pull it out then check inside the CCU for water.

The P0230 fault is fuel pump primary circuit fault.

This will give you the cutting out problem, fuel starvation.

The pump is under the back seat on top of the fuel tank, but cables run down under the carpet so may have been affected by the water.

Edited by dieselnut on 13/04/2019 at 15:42

Audi A4 B6 - Stuttering engine then stall - 2004 1.9 TDI - MarkHumphreys

Make sure you check under the front passenger carpet.

There is thick foam under the carpet which holds loads of water, then underneath all that is the CCU ECU which will be laying in water.

The plugs go green then wires start to fall off.

Pull it out then check inside the CCU for water.

The P0230 fault is fuel pump primary circuit fault.

This will give you the cutting out problem, fuel starvation.

The pump is under the back seat on top of the fuel tank, but cables run down under the carpet so may have been affected by the water.

Thank you for your reply, I'm taking the whole carpet up on Monday and checking/dryingeverything so I will report back and let you know.

Audi A4 B6 - Stuttering engine then stall - 2004 1.9 TDI - Big John

Thank you for your reply, I'm taking the whole carpet up on Monday and checking/dryingeverything so I will report back and let you know.

Check the original source of the water as well - remove top of the plenum chamber and the battery to really make sure the drains will remain clear.

Also thoroughly check the brake servo for signs of rot and read this as I think with this age of Audi A4/A6 the setup is nearly the same as the Superb mk I :-

https://www.briskoda.net/forums/topic/152490-water-ingress-problemsolved/

Electrical problems after water ingress are well documented. When removing carpets be careful with any connecting wires and PHOTOGRAPH/document everything especially electrical connections. The reason is - it is possible for corroded wires to part company and it's quite hard to work out which colour wire connects where! As above check for water in the CCU.

Good luck

Edited by Big John on 14/04/2019 at 23:26

Audi A4 B6 - Stuttering engine then stall - 2004 1.9 TDI - dieselnut

" The seal rots between the plenum chamber and the car interior "

I think Big John meant to say between the pollen filter housing & the body.

Completely remove the pollen filter housing, the usless original foam seal will have rotted to dust.

Replace it with a rubber seal or silicon once you have completely cleaned up all the crap.

Water runs from there, behind the carpet, accross all the wiring & into the passenger floor swimming pool.

Audi A4 B6 - Stuttering engine then stall - 2004 1.9 TDI - Big John

Er - I did - was just trying to show it was between plenum and interior as this is the water that leaks in.

Edited by Big John on 15/04/2019 at 13:59

Audi A4 B6 - Stuttering engine then stall - 2004 1.9 TDI - dieselnut

Pollen filter is mounted horizontally above the plenum on the near side & a different source of water leak.

Edited by dieselnut on 15/04/2019 at 15:04

Audi A4 B6 - Stuttering engine then stall - 2004 1.9 TDI - elekie&a/c doctor
The main cause of the flooding is a build up of water in the plenum area , is a blocked rubber “tulip” valve that sits under the battery support frame . Remove it and problem sorted. Water entry via the cabin filter is a result of this problem.
Audi A4 B6 - Stuttering engine then stall - 2004 1.9 TDI - edlithgow

For context, my past cars have included a Marina 1800 and a Lada Mk1 1200.

My current car is a rather decrepit 1986 Daihatsu Skywing.

Unlike Audi, these are not generally regarded as high quality cars.

This sounds like appallingly bad design to me.

Audi A4 B6 - Stuttering engine then stall - 2004 1.9 TDI - MarkHumphreys

So, I took up the carpets and there was literally a couple of litres of water submerging the wiring under the carpets. I couldn't see any particular damage to the wiring but I got all the water out. I checked the CCM and this was bone dry inside luckily. The car is now starting and running without any particular issue but due to the previous stalls, I've lost my confidence with driving it until it's been given the all clear so I'm taking it to my local garage tomorrow for a proper check. Thanks everyone for your help, it us much appreciated.

Audi A4 B6 - Stuttering engine then stall - 2004 1.9 TDI - dieselnut

Pleased to hear the car is running ok now.

While you have the carpets up you need to check for leaks.

Play a hose on the windscreen & check in the footwells for any water dripping down.

The pollen filter housing in a definate source of leak on the passenger side.

The ECU, cables & bonnet release cable on the drivers side.