Mk3 TDI golf 90bhp 1996 poor starting and power loss

[Cakie]

Hi
can anyone please help?
My 120k Tdi has been bad to start for some time and was very flat when running. I have checked for fault codes but there are non recorded, glow plugs checked out ok but the ECU doesn't switch them on (8 deg aprox).
After finding very, very tiny metalic particles in the fuel cut off, I blamed the injector pump (VE type no lift pump in tank) so changed for a serviced secondhand pump and had the injectors serviced. Still bad to start and no power, if it was petrol I would say it seemed retarded!
what temperature should the glow plugs come on? I have by passed the glow plug relay and that didn't help.
i have changed the fuel filter and blown all the lines out, i get plenty of white smoke when tring to start her up.
I am at a loss.

Cakie

[zollaf]

welcome to the forum.
right, presumably she cranks over well when cold ? does any smoke come from the exhaust whilst she won't start. best to get someone else to try to start and you watch and smell the tailpipe. if there is smoke or it smells of diesel, then fuel is being injected but not igniting.
once running, you say she lacks power. is this all the time or just for a short time ? could be an air leak letting fuel drain back out the pump/filter. possibly leak off pipes perished.
right, read your post again and you get white smoke, so diesel is going in and not igniting. thats either plugs, but you have bypassed them, or lack of compression, or again aerated fuel. check the starting with the header tank cap removed, does the water move or bubble ? has it had a timing belt- possibly a tooth out ?

[Cakie]

welcome to the forum.
right, presumably she cranks over well when cold ? does any smoke come from the exhaust whilst she won't start. best to get someone else to try to start and you watch and smell the tailpipe. if there is smoke or it smells of diesel, then fuel is being injected but not igniting.
once running, you say she lacks power. is this all the time or just for a short time ? could be an air leak letting fuel drain back out the pump/filter. possibly leak off pipes perished.
right, read your post again and you get white smoke, so diesel is going in and not igniting. thats either plugs, but you have bypassed them, or lack of compression, or again aerated fuel. check the starting with the header tank cap removed, does the water move or bubble ? has it had a timing belt- possibly a tooth out ?

Hi Zollaf
Yes I get white smoke when cranking and I have checked timing with cam locked and pump also, crank was about 2 mm out from lining up.
the car has lost more and more power and gradually got worse at starting although it turns over pretty quickly.
I have also replaced a lot of pipe work as I wondered if it had perished.
i will check for bubbles in the cooling system tomorrow that is something I haven't looked at.
i could do with some values for engine sensors so I could check them out but no one seems to have them.
many thanks for you help.
Cakie

[Doctle Odd]

you need to reset the timing, do you have access to a dial gauge? do you know when the timing belt was changed and was it done properly? by properly I mean was the cam sprocket loosened before the belt was tensioned. you can adjust the pump timing with the engine running, there's plenty of write-ups available

[Cakie]

you need to reset the timing, do you have access to a dial gauge? do you know when the timing belt was changed and was it done properly? by properly I mean was the cam sprocket loosened before the belt was tensioned. you can adjust the pump timing with the engine running, there's plenty of write-ups available

Hi Paul
i followed a procedure for changing the belt that just listed locking everything and I marked the belt and transferred that onto the new belt. I was told that the car can be dynamically timed but that that, only trimmed the setting. I guess I could have cured one fault ( pump) and given myself another!
Can you direct me to any information that would be helpful as I have had so much conflicting.
yes I do have a dti
Regards

Cakie

[Doctle Odd]

http://pics2.tdiclub.com/pdf/a4timingbelt.pdf

different car same engine you lock the camSHAFT but the sprocket must be "freewheeling" to get the timing spot on. There's plenty of older Audi's and VW's that drive like a commer van because the backstreet mechanic didn't time them properly, If you see tipex it's probably off the timing!

Here's a link to setting up the pump using a dial gauge

vincewaldon.com - HOW-TO: Set The Injection Pump Timing

[Cakie]

http://pics2.tdiclub.com/pdf/a4timingbelt.pdf

different car same engine you lock the camSHAFT but the sprocket must be "freewheeling" to get the timing spot on. There's plenty of older Audi's and VW's that drive like a commer van because the backstreet mechanic didn't time them properly, If you see tipex it's probably off the timing!

Here's a link to setting up the pump using a dial gauge

vincewaldon.com - HOW-TO: Set The Injection Pump Timing

Paul
many thanks for the link to this excellent site. I assume that the cold start knob is for USA cars only (like a choke?).
I will order the fitting for my DTI tonight, so fingers crossed this will work.
Thanks for the help

Cakie

[Doctle Odd]

Hi Cakie
The cold start knob was on jettas ventos etc for a while it advanced the timing I think. the idea is the same these cars didn't have a vp pump but thats the way to do it. there used to be a writeup on clubtdi but i couldnt find it