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Just looking around the engine and notice that the egr valve doesn't have clips holding the pipes on. Are they supposed to? 

The other end does? Must have been taken off to replace the egr valve that was potentially one of the faults here. 

Screenshot_20191019_104114_com.android.gallery3d.thumb.jpg.51aa66d088d45d95937753cd96048075.jpg

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Yeah, all looks normal. Check the voltage in that supply plug on the egr controller. Not sure what it needs to be in there, but i think from memory, it's 0 and 12v when running idle.

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So currently I am installing a new backbox. 

In the image shown below is how I bought it so at least it won't kill me when I drive it around with all the fumes. 

Screenshot_20191021_114452.jpg

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Managed to get the car on ramps and cut through the section of the pipe. 

I got a new exhaust from eBay, quality is questionable but it will do for a few years I'm sure. 

Only problem is, a bloody cross member in the way. 

So that stopped play trying to thread the exhaust over the top. Need more ground clearance :( so need someone with a lift. Pain in the ass 

Screenshot_20191021_114443.jpg

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6 minutes ago, Sarahs Lupo said:

Managed to get the car on ramps and cut through the section of the pipe. 

I got a new exhaust from eBay, quality is questionable but it will do for a few years I'm sure. 

Only problem is, a bloody cross member in the way. 

So that stopped play trying to thread the exhaust over the top. Need more ground clearance :( so need someone with a lift. Pain in the ass 

Screenshot_20191021_114443.jpg

Got a link for the ebay exhaust? Need a midbox myself but may opt for a system if it's cheap.

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5 minutes ago, Stephenmacleod said:

Got a link for the ebay exhaust? Need a midbox myself but may opt for a system if it's cheap.

I have a link but mine is only a back box part. 

What I did was use a website for the part number and then cross referenced on eBay. 

This is the website for the parts. 

https://volkswagen.7zap.com/en/rdw/lupo++lupo+3l+tdi/lu/2004-441/2/

 

And my exhaust. 

https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.co.uk%2Fulk%2Fitm%2F150480071977

 

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Update. 

 

Fitted the exhaust at the local garage. 

Fumes are still higher than I'd like but that is also a factor of the engine problems. At some point a full system will be purchased as The wife has asthma and she has a noise like a dog haha. 

To my annoyance I booked the car into a local auto electrician to see if they can give me any pointers where this earthing problem is coming from . 

I want the thing fixed so I can start to enjoy it!! 

Hopefully they will know more tomorrow. 

If I can't  get this diagnosed for a reasonable amount of money then we might have to cut our losses and sell  :( :( 

Not sure what else I can do with my limited knowledge of electrical systems. 

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Still Updating this:

Had the car in the electrical diagnostic people, and apparently found the fault to be the ECU.

A used ECU was purchased off Ebay, and apparently the faults I had didn't move and so it was clean. The ECU is now being cloned, I can only assume that means I don't have to get a new key/ disable the immobiliser.

All well and good I can pick the car up very soon.

Will update when I get the car back!

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Update: 

Found some NGK ones that seem to be the correct for my car. 

Gonna order them when I can.

Needs a new IAT sensor I rekon, 

Window switch

Front grille 

Boot lid. 

Also bought some cheap GTI wheels for a song. Just need new tyres. 

Thought this car was suppose to save me money haha 

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Keeping this going:

Not much has happened recently. 

Got a new IAT sensor which didnt do anything.

Connected to my cheap code reader and did some logs. It looks as if the temperature sensor reads 215 degrees when i got my foot on the gas,, but if i coast of dip the clutch down, it returns to the normal levels.. So must be a voltage thing.

I have downloaded VCDS Lite and have a cable on order. Im hoping this will be more helpful. 

My electric door switch seems to be linked to the runners, its like to go half way up from the bottom, then get stuck and go back down, so im assuming there is an obstruction or just need a lube.

bit cold for me to start messing with that so for now, i will concentrate on the IAT sensor. 

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Bump:

 

Downloaded VCDS and got my cable connected. 

Only fault with the car comes back as P1161 - Manifold Temperature sensor (G72) 

Not sure why my cheap code reader got a different result but im trusting the VCDS. 

Now i just need to know where to check this bloody fault.

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Still here! 

Loving MPG life! 

 

my fault is still there.. havent had time to diagnose correctly... havent even checked the wiring etc.. been too busy using it as a daily beater!

Got some new wipers today and an Air filter - i also added all the service history to a nice Excel spread sheet which tells me a new air filter is needed after 25k miles!! 

I need to get kick @mk2 into sorting out the pics for cambelt change or at least gimme a hand haha! i think one of the idlers is making a metallic rattle sound.. it is over due by 25k also!! 

****! 

Also still need to fit the glow plugs (doh!) 

Lovely car just keeps going and going, just wish i had to time to sort the niggles out!! 

 

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Update on the blue beast. 

Cambelt kit and auxillary belt completed yesterday by a local vw  specialist. Never got round to finding pictures and the kit etc etc so paid for the privilege. 

overall the car is brilliant. Looking to swap out these awful coilovers to someone on facebook who are looking for lows. Honestly the ride is horrendous. 

And finally... the engine light is still on.. STILL need to investigate the wiring to the manifold sensor.. 

i did change the sensor as that was cheap but fault still exists. Need some pointers.

Im also going to say its probably sapping power . had a little whiz in my mates lupo SDI and his really pops! makes myn feel broken :(:(:( 

 

 

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