T4 1.9d Fuel pump timing.

[Scotsman]

Today I was at the VW garage to have my engine timed. They have set everything up perfectly but they say I have to find a specialist to set the diesel pump up so that it is timed perfectly with the engine. They say that they cannot do it at the VW garage,which I find strange ? does anyone know where I could get this done ? My T4 is from 1995 and has just had the engine rebuilt along with a new starter motor,dynamo,fuel filter and the fuel pump was revised.

Regards

The Scotsman

[Pascal-141]

A VW dealer that could not do the timing of the fuel pump ?
You say that the engine and pump got a revision , who did that ? Because i have my doubts about the knowledge of your garage if they are not even capable of timing the pump ...

[Geert G]

@ Scotsman:
Were do you live? If it's in my area (across the German border nearby Nijmegen/ Venlo) I can help.
I have the micrometer, to stick in the pump, for the adjustment.

Other option:
You told, it' s a recondition engine.
Most engine rebuilding shops have the old skills to adjust a diesel pump.
Why you don't go to the engine shop who has recondition your motor?

Last option:
Google at Bosch diesel service shops. They have the skills & tools as well.

Truly but sad: The young generation mechanics, ain't 2b able adjusting a diesel pump at the static way.
Because it's old school, at these day's.
In today's modern cars, the whole diesel injection-system is controlled by electronic components. And that means:
Adjusting parameters with a VAS or VAG COM computer.

Best regards, Geert

[Scotsman]

Hi Pascal 141 and Geert G,

I too was very surprised that the VW Garage in Breda could not time the diesel pump. They told me to find a specialist that can. They set the engine timing perfect and now at higher speeds the Van goes smoother,but when the engine ticks over when I have stopped then there is smoke coming out of the uitlaat and the engine does not sound smooth. However in the mornings my van will not start without Start Pilot. This was the reason I went to VW,my van was not starting in the mornings. Once started then it runs fine all day.
So the situation now is ...... after going to VW .....my van still won't start in the mornings,its running with smoke when still,but at higher speeds it sounds and runs well. Before going to VW my engine would tick over without smoke coming out of the uitlaat. There is some hope ? tomorrow my Van is booked into the revisie garage that revised the pump......so here's hoping :-)

I will update the results.

Regards

The Scotsman

[Multivan Generation]

@ Scottsman,
have you considered to make an appointment at Caron's in Made?

[Geert G]

It sounds like, the distribution doesn't stay on time.
Properly the camshaft/pump wheel is been adjust one or two tooth wrong.
The ticking wot you hear at idle, can be a contact between valve & piston, if the engine doesn't stay on time.
Valves mostly bend, after piston contact.
You lost compression, an that can be explain that your motor fail with the cold start.

Second possibility:
The diesel pump delay function doesn't work properly.
For a smooth cold start, the injecting moment must be delayed.
This is a mechanical device, inside the diesel pump.

Or the wrong pump is been fitted.
You need pump part-number Bosch:
07/1994 -> 04/1995 Chas.nr. -> 70..SH113 565 Bosch 0 460 494 356
05/1995 -> Chas.nr. 70..SH113 566 -> Bosch 0 460 494 417
Spare part number for those two: Bosch 0 986 440 257 (Mosley factory reconditioned pumps)

Third option:
A couple of your diesel injectors been worn out. ( they didn't recondition these ones, at the engine rebuild, did they? )
A worn out diesel injector doesn't fine-spray the diesel fuel, but they piss at the piston.
This creates a rattling sound, and black or blue smoke as unburned diesel fuel.
Aider, this color of smoke also when your engine or pump isn't on time.
When injectors worn out, the possibility is there, for air in the fuel system, after a night.
With air in a diesel-fuel system, your engine will struggle to start.

Anyway, in your case: something is seriously wrong.
As Mulivan Generation recommended: look for a specialist
(not a VW dealer, our stuff is to old for then)

Options in Breda:
Broos Revisie BV http://www.broosrevisie.nl/" onclick="window.open(this.href);return false; or Keers Motorenrevisie: http://home.online.nl/~wimpeg/info.html" onclick="window.open(this.href);return false;

Greetz, Geert

[Geert G]

Caron in the place Made is also a good one: http://www.caronvw.nl/" onclick="window.open(this.href);return false;
Specialized in Volkswagen commercial vehicles

Something else:
After I read your text again, one thing is weird:
It's not proper written English.....
You're not a British bloke, are you?
Not perhaps a regular Dutch cloggi ?
Who tray to speak English??
I was wondering this, but not a problem at all.

Greetz, Geert

[Multivan Generation]

@ Geert,
ik heb hem Caron in Made al aanbevolen.
Die weten wat ze doen

[Geert G]

Peter, ik zag het ja....
Ik was tegelijkertijd met jou aan het tikken, dus dat heeft zich gekruist.
Dus heb ik VW Caron nog maar effe bevestigd.
Sorry

[Multivan Generation]

[Scotsman]

Hi Geert, my Van is at this moment in Broos in Breda, Maikel Broos is setting my fuel pump himself. He was the one who revised it last month. Since VW timed the engine on Tuesday my Van is running very smooth but starting is still a problem and smoke (blue ) comes out at low revs. Once I am up at 3rd,4th and 5th gear then all is well.

I will update the outcome later.

Regards

The Scotsman

[Multivan Generation]

Keep the address Caron in Made in mind for future reference..

[Scotsman]

Picked up the my Van from Broos in Breda and its going great,no more smoke :-) and its running very smooth in all gears. However it is still not starting ( original problem ) Broos reckon that the problem lies in a relay that controls the amount of time the glow plugs light up for. They reckon that the plugs are not heating up for long enough. So tomorrow I will go to VW Breda to see if they can find this fault and fix it. This whole saga has now been going on for 6 weeks and the fuel pump saga for 3 weeks :-( so far 3000e gone,1200e on this fuel pump alone :-( ........finally ? tonight I have noticed oil drips under my Van,not sure if this relates to the fuel pump timing repair today ? a strange coincidence,I'll ask VW tomorrow. The fuel pump was altered by just over 1mm and now the Van is going super.

Regards

The Scotsman

[Geert G]

Very easy to test your glow plugs:
Remove te copper power live rail from te glow plugs.
Take a peace regular electrical wire. You connect one site at positive + on your battery.
The other site from this wire, you strike over the small nut or treat from the glow plug.
If its sparks, the glow plug is fine. No sparking when you strike.....this plug is dead.
I'm not wondering, if 3 or 4 plugs been past away. So long the motor has been starting, nobody looks after.

You need four new glow plugs: Bosch Duraterm 0 250 201 032 for your Van.
Every car parts shop sell these parts. Like Brezan, Iberma IRA Automaterialen, Slager Automaterialen.
Half the price as by VW, and the same quality as OEM. Beru GN857 ones are also fine. OEM VW glow plugs are Beru's
Torque the new plugs with a ring-spanner hand tight, not more, maximum torque: 10NM
Reconnect the copper live rail.
Test with a car test light, that you have power on the copper glow plug rail or not........after you turn on the ignition key, with a cold engine.
If not, glow relays or the temperature sensor fails.

Good luck, Geert

[Scotsman]

Hi Geert,

I picked up my Van on Thursday,Broos had made an adjustment o the fuel pump of 1.1mm. This made a huge difference to the overall running of the engine and stopped the smoke that was billowing out in the low gears. On Thursday night the Van ran smoothly. However on the Friday morning the Van would not start,so I put Start Gas in the air vent and it started up. I then noticed that their was a diesel leak,as there was diesel under the van,and not a small amount :-( On my way to Boos to have things checked out my engine started to make a strange noise so I immediatley stopped and called the ANWB. They checked a few things and sourced the problem with the starter motor which had burned out,my starter motor is new ! 6 weeks old. They reckon that there is a problem with the ignition system which is keeping a flow of electricity from the battery to the starter motor when the van is running ? The ANWB took the start motor out and gave me a bump start,my van started fine and I drove to teh VW garage in Breda where on Monday they will diagnose the problem. Last Tuesday they told me the problem with starting was down to the timing of the engine and pump. I have now had a month of starting problems with the van and it seems that the fuel pump is not the source of the problem.
EXTRA INFO: When the problem started,it was easily resolved with start gas in the morning. Then the van would start with no problems all day. But leaving it overnight meant it would not start without start gas.....apart from on 4 occasions when it did start first time in the morning ???
In the last few days it would only start with start gas,not just first thing in the morning ? The ANWB checked the stroom for the glow plugs and that is fine.

This start problem with my van has now resulted in huge financial costs which will increase on Monday at VW as a new starter motor is 335e + fitting + diagnoses of problem source.

All in all Geert ,its been a nachtmerrrie

Regards

The Scotsman