Starting problems?

[Patrick]

Got problems with a 1.6 TD. Glow plugs are fairly fresh, and show a draw of close to 50 amps. Engine is supposed to have about 200,000 km on a factory rebuild. Burns absolutely no oil. Doesn't want to start below freezing , even though it's cranking over at a good speed. started fine this morning plugged in, wouldn't have otherwise. Does have a noise I don't like, thought maybe a lifter, but maybe it's a bad injector?? Car runs good and gets decent mileage once it's running, better mileage than an identical car with a 1.9 that starts a LOT better.

Current plan is to have my stock of injectors pop tested to find four good ones, pull the injectors and do a compression test. Put the known good injectors in when I put it back together assuming the compresssion is okay. Any other ideas?

[mortskeg]

Patrick-
If your engine is running well once it is started, then I would suspect your glow plug system, especially if it'll start when plugged in but not otherwise.  I had this happen on my pickup on 2 occasions, the first was because one of the screws that tightens down on the glow plug fuse had come loose and was not making a good connection, the second time because the fuse had 'blown' (hairline crack).  In both cases it was an easy fix, the fuses are pretty inexpensive.

I'd bypass the relay and the fuse by jumpering between the battery + terminal and the glow plug buss, so that you know that they are recieving juice.  Give them a good 20 sec and start cranking.  *trick I learned from Dr. C* If it still doesn't fire then you'll know that the problem lies elsewhere (or your plugs are bad but you said they are new so probably not)

Here's a pretty good link where a bunch of us hit up alot of reasons that the diesel would fail to run-
http://vwcaddyforum.com/showthread.php?t=3828

Hope this helps.

[Patrick]

Thanks, but like I said, it's not the plugs. The fuse was replaced with a 50 amp breaker a while ago, power is getting to the plugs, and I know the plugs are okay, like I said they're drawing almost 50 amps as a group.

[chrissev]

Thanks, but like I said, it's not the plugs. The fuse was replaced with a 50 amp breaker a while ago, power is getting to the plugs, and I know the plugs are okay, like I said they're drawing almost 50 amps as a group.

what is the compression like?  ever tested it?  It has to be pretty close to the factory specs for the engine to start when it is cold.  If it is low, forget about starting below zero.

[Patrick]

Does anyone here read before they post?I said in the original post checking the compression would happen this weekend, the injectors would be replaced just because while I'm at it. Also said it burns NO oil, so I'm assuming the test won't show a problem. I wanted to know if I'm missing anything obvious BESIDES glow plugs, compression, injectors.

BTW, it is getting fuel when it's cranking over and won't start.

[RedRotors]

This post belong to the Troubleshooting section not power enhancement one.

Marc/
Site Admin.

[Patrick]

Yup, sorry! Don't know what I was thinking. Sorry if I sounded a little snappy in that last post too. Long day.

[Patrick]

Update:

Compression is about 425 on all four cylinders. Injector nozzles eroded fairly severely, might be the biggest part of the problem. Did find one bad glow plug, guess my ampmeter is off, three glowing shows almost 50 amp draw!

Putting it back together after supper.  What's the torque supposed to be on the injectors? I'll keep looking, but I don't have a diesel manual.

[Patrick]

Found the torque value I needed in an old Chilton's manual. Engine starts a lot better, and  sounds better too. Had a noise previously I couldn't identify, thought maybe it was a lifter. I'm now assuming I had at least one bad injector. Maybe a bad spray pattern took out the glow plug?

 Sounds like a whole different car!