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Author Topic: changing IP shaft seal on 1999 TDI  (Read 5948 times)

Reply #15August 17, 2014, 07:51:43 pm

paolomarks

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Re: changing IP shaft seal on 1999 TDI
« Reply #15 on: August 17, 2014, 07:51:43 pm »
Hello again,
So I took out the IP and completely resealed it.  I re- installed it so that at TDC the camshaft slot is parallel to the head deck and the timing pin slides through the IP pulley and smoothly into the backing plate hole.  I primed the IP by using my vacuum extractor on the IP return line, and then cranked the engine while bleeding each of the hard lines.  Engine cranks fast and white smoke comes out the exhaust, but no start.  It will catch once or twice but that's it.  Engine has 260,000 miles and compression is untested.  I've heard that TDI's don't need the glowplugs to start when it's  warm weather like it is now.  I haven't tested the plugs, is it possible that that's where the problem lies?  Is it possible that the IP timing is 180 off?   Thanks in advance,  Paolo.

Reply #16August 17, 2014, 08:39:49 pm

libbydiesel

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Re: changing IP shaft seal on 1999 TDI
« Reply #16 on: August 17, 2014, 08:39:49 pm »
If you pulled it apart as deep as the camplate, it is possible to assemble 180° out.  Otherwise, when you say the cam was parallel, was it aligned with the edge of the head or offset from it?  If offset, then it would be 180° off.

Reply #17August 18, 2014, 12:22:28 pm

paolomarks

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Re: changing IP shaft seal on 1999 TDI
« Reply #17 on: August 18, 2014, 12:22:28 pm »
Hello,
I just went out and disconnected the no.1 hard line at the fuel distributer.  Next I turned the engine over by hand until the IP pulley was just before the point where the pin slips in,(about to inject no. 1 )  then I had someone bump the starter less than 1/2 rotation of IP pulley. A dribble of fuel came out indicating that indeed the pump is not 180 out.  Did this a couple of times to be sure.
  The camshaft is also not 180 out as the slot is even with deck and not offset and the lobes of cylinder 1 are both up at TDC.
   When I turn the key to the start position the glowplug light illuminates for less than a second and then goes out. Does this mean that the glow plugs are energized for only 1/2 second or is it just an idiot light saying that the glowplugs are indeed working?  I put my clamp- on ammeter on the red line going to the glow plug harness and didn't see anything while in the start or crank positions.  Glow plug fuse looks fine.
  I'll let it crank fast for 5 or 10 seconds and sometimes it will catch briefly before resuming normal crank speed/sound.  Plenty of white unburned fuel  coming out the exhaust pipe, but no start.  I had a Saab 900 (gas of course)  that had a plugged cat converter that would do the same, too much back pressure.  Could this be the case here as well?  Thanks, paolo.

Reply #18August 18, 2014, 06:28:31 pm

libbydiesel

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Re: changing IP shaft seal on 1999 TDI
« Reply #18 on: August 18, 2014, 06:28:31 pm »
Glowplugs are a red herring.  TDIs won't need glow plugs until ambient temps are down around freezing. 

Reply #19August 19, 2014, 09:26:35 am

paolomarks

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Re: changing IP shaft seal on 1999 TDI
« Reply #19 on: August 19, 2014, 09:26:35 am »
I had heard the same thing about TDI's , but just for kicks I went out and wired the glow plugs directly to the battery and tried cranking her.  Where  before, it caught only once or twice, now it was on the verge of running and when I stopped cranking it actually ran for maybe 1 second!  So glow plugs are not the answer, but does this give a clue as to the underlying problem.  Also I noticed that the tachometer was pegged during cranking, even though I'm sure the engine never went more than a fast idle.  Is this also a clue as to what's wrong. Paolo.

Reply #20August 29, 2014, 07:48:39 pm

paolomarks

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Re: changing IP shaft seal on 1999 TDI
« Reply #20 on: August 29, 2014, 07:48:39 pm »
Hello again,
Is it normal for the fuel shutoff solenoid to click open when the key is turned to the on position,but then click off after 5 seconds even though the key is still in the on position.?  Paolo.

Reply #21September 01, 2014, 10:33:27 am

paolomarks

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Re: changing IP shaft seal on 1999 TDI
« Reply #21 on: September 01, 2014, 10:33:27 am »
Hello,
I got it up and running! Ended up putting a 3-5psi lift pump before the IP and that seemed to do the trick.  It smokes more than it should however. It's a white unburned diesel smoke.  I realigned the quantity adjuster cover back to my scribe marks, but don't have a vag com to do IQ.   I read somewhere that you can download a free version from Ross tech?  Alternatively, can I tap the cover one way or the other until smoke reduces and call it good?  Getting close! Paolo.

Reply #22September 05, 2014, 12:25:00 pm

Toby

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Re: changing IP shaft seal on 1999 TDI
« Reply #22 on: September 05, 2014, 12:25:00 pm »
This all sounds like very retarded IP timing. I would bump it up a bunch and see what happens.