Engine running rough and cutting out

Michael1983

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2002 E320 cdi avantgarde estate
I was not sure if I should post this here or in the electrical section but I need some help please

I have a 2001 E320 cdi which i have invested a great deal of time and money into doing the car up however after the recent work I carried out the car has developed a fault when it was taken for MOT. initially the car lost all power when the local mechanic was driving it back from the test station. I was able to get this issue to clear and the car drove fine for a bit until one morning I went to the local shop and when I went to drive home again the fault was back and quickly developed to the car cutting out.

Initially seeming like a fuel issue as no faults from the ECM on the dash I ordered pressure sensor and regulator as I had done the rest of the fuel system last year with recon high pressure pump, new fuel lines or seals and cleaned and reinstalled all 6 injectors using correct torque procedure. The morning I went to install these the problem had gotten worse and these parts did not solve the issue I put the car on my carsoft code reader and it came up with P1662-032 injector 2 under voltage which later changed to injector 2 open I changed injector 2 with another injector to no avail then changed the entire engine loom.

Initially after changing the loom and getting the air out of the fuel system the car ran for 2 minutes before the fault came back though not as bad as before and it only shows the P1662 code again. Before it went for MOT it had throttle sensor, alarm siren, tandem pump, wings and bumpers from a donor car, I also had the transmission selector apart as i was looking for a reversing switch due to an issue with my reverse lights and since this fault has appeared I've also noticed that the tiptronic function on the selector does not work.

I am now at the point of trying a ECU set change to rule out the ignition and ECU as the car was jump started when it was taken to the mechanics and he put a charger on it over night at his workshop. I should probably add that after the alarm siren was installed the alarm malfunctioned and would not turn off so the battery had to be unhooked however the siren continued to make an odd noise for several days I guess due to back up power inside it.

Advice from anyone who may have had a similar issue would be greatly appreciated as of tonight it will start but sounds knocky as if the mixture is wrong and car struggles to maintain the revs which will drop to a virtual stall then recover before dropping again and cutting out
 

mersum1es

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remove that alarm siren...

probably undervoltage/grounding problem, and/or ecu probelm if you are 100% sure wires and connector from ecu to injector is now solid
 
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Michael1983

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Thank you I will be as it was causing issues ever since installed.

before I go down the route of changing the ECU does the big ground wire from the transmission to the body affect the injectors or do they have all there ground supplied via the connector?
 
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Michael1983

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Just wanted to drop an update as there's nothing worse then searching your problem and the thread doesn't show a conclusion.
Fitting a second hand Ecu, steering lock and barrel fixed the problem.
 

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