New to me 1.6TD

[steevz]

Just bought another 1.6 TD. 85 Jetta, no rust.. good condition.

I am having some trouble though and am left wondering where to look next.. It's definitely getting fuel starvation (I think)..

Here's the situation:
The car starts, runs for a few minutes then starts coughing, sputtering, and dies. When it dies 1000s of tiny little bubbles come rushing out of the pump inlet and up the hose towards the filter.

What I've done so far:
Rig up an IV to the pump. 8' clear line from bottle of diesel. Started and ran fine.
Rig up an IV to the filter. Same results, started and ran fine.

Then I preceded to remove the fuel pickup and cleaned out the screen. It was all gunked up and filthy. Took some cranking to start, ran fine once getting fuel again until sputtering and dies with air coming back up the hose.

Next, I deleted the water separator by the rear wheel. Same result, don't stay running.

Once all the bubbles settle and I can start the car again I've tried cracking the injectors just they just keep spitting out little bubbles and don't seem to clear up and eventually the car will die again.


Are there any more likely culprits for causing these symptoms? I'm in need of ideas.

Thanks.

Edit: Also, I should note that when driving the car it doesn't feel like it's lacking any power, and if throttle isn't allowed to drop too low it won't die.

[guy plain]

 dose the return lines go back to the filter? if so check those... that seemed to be my problem awhile back...they didnt even look like they leaked out...but where not tight on those little tubes on the injecters...i trimed the ends and most of my air teoubles stopped... i also had a leaking fitting on the filter..

[steevz]

Well, I trimed both my lines at the filter. Return lines just goes straight back to the tank.

Tomorrow I'm replacing all my lines with clear. Hard to filter, to IP, and IP to hard return. Should make life easier.

[steevz]

Replaced all the lines with clear. There is constant foam/tiny air bubbles from the return line out of the IP back to the tank. Intake is air free except when it chokes out and all the tiny air bubbles come back out of the IP inlet.

Ideas?

[damac]

I went through the same steps as you after I got my first jetta  home.  Although I didn't have as bad a case as you, I had the air bubble problem.

In my case I went through my original abused pump on the car, another used one that sprung a leak as soon as I installed it.  And even after blowing out all lines, replacing new runs from engine bay to tank and all clear hose unions.

I also was baffled to see a chinese cheap fuel filter give me air restriction problems right from the get go in a bucket.

I even got my injectors rebuilt a few months into owning the car and installed a new vw return line kit.  What was crazy is I used to be able to get out of the car after shutdown sometimes when  hot and put my ear near the pump and hear hissing for almost 10 seconds.

I also saw the problem get worse while on the car with its fuel lines vs. a bucket which is why I ran straight new runs thinking I was missing some pinhole leak.

For me I also got another used pump from a forum member that started to leak after I put it into service and I replaced just the high pressure end oring and wouldn't see fuel drips anymore.

I finally got sick of it and busted down another pump with fresh mainshaft bushings, cleaned things up and resealed everything with a kit.  What do you know to this day the fuel stays primed at the pump and I don't get an introduction of air bubbles.  I used to go out for a cold start and the fuel would drain away from the inlet of the pump so I wasted juice with glowplugs and the starter as it tried to reprime itself, then cough to life for a bit and clear itself out.

[steevz]

Well, I ran it again today with the feed and return in a bucket. It ran all the air out of the lines. Return line was pure fuel as well as intake and it idles fine until shut down.. more then 15 mins. So, there must be a blockage somewhere... going to get the return lines blown out tomorrow.

[ORCoaster]

Sounds more like front end shaft seal trouble to me.  Rebuild in order, buy the kit and tear into it.  My suggestion.

[steevz]

I have an NA pump. Can I put that in while I rebuild the other?

[Blocksmith]

I have an NA pump. Can I put that in while I rebuild the other?

Yep. Most definitely. Lotta people (myself included) run n/a pumps with turbos. Technically speaking it's not quite as ideal, but in all reality it works just fine. Just a little more smoke until the boost kicks in is all.

[steevz]

Blew out return lines.. were clean, and turned out to be the check valve, deleted it, idles fine now. Just gotta check oil pressure high and low cause I got both lights blinking/buzzer.

[R.O.R-2.0]

I have an NA pump. Can I put that in while I rebuild the other?

Yep. Most definitely. Lotta people (myself included) run n/a pumps with turbos. Technically speaking it's not quite as ideal, but in all reality it works just fine. Just a little more smoke until the boost kicks in is all.

no..

more like ALOT more smoke while off boost..

my car would pour a smokescreen with the n/a pump.. now with a TD pump, no more smoke screen.

[steevz]

Damn.. low oil pressure. 0psi on my 0-100psi mech gauge at idle. only 12-18psi in between 2000-2500 rpm. The wife had her foot on the throttle and was watching it but she was having issues. All I know it that it's low.

[steevz]

Gah, pulled the oil pan. Then soft pieces of metal in the pan and a big piece clogging the oil pump screen. Rod and main bearings are in excellent condition.. got some new intermediate bearings, going to try and switch out the outter bearing at least.

[R.O.R-2.0]

Damn.. low oil pressure. 0psi on my 0-100psi mech gauge at idle. only 12-18psi in between 2000-2500 rpm. The wife had her foot on the throttle and was watching it but she was having issues. All I know it that it's low.

HOLY CRAP!!

thats WAY WAY LOW!!

i used to see 6-8psi at idle, i thought that was low, but 0 psi, now thats low..

[steevz]

Okay, well I have everything apart. I wasn't exactly sure how to get the IM shaft bearings replaced, hard to find solid information on them. I just want to do the outer bearing for sure..

How does one get the old bearing out of the block without causing any damage to the surface the bearing is in contact with? I can feel the surface of the outer bearing has flaked by just rubbing around it with my finger. I'm hoping the inner will be okay.