VW T4 Forum - VW T5 Forum banner

1 - 8 of 8 Posts

·
Registered
Joined
·
189 Posts
Discussion Starter #1
Since just before Christmas my engine has developed a fault.
The van cut out in the City and the AA came and restarted it (easy start) and followed me home (40 miles away).
Once home he put his diagnostic machine on it and found a camshaft sensor fault.
This fault has always been on my engine since I got it 3 years ago and has ran 32,000 miles without issue, so this was not the fault.
He gave the diagnosis as "fuel related"!
It kept cutting out so I was told to check the tandem pump (which was rebuilt 6 months prior) I found the central seal had blown, which was my fault for installing it in the wrong way round!
This has leaked oil into the fuel system, so I hoping had found the fault drained the oil contaminated fuel changed the fuel filter and filled with fresh fuel.
The problem persisted so I was told to replace the injector loom as this is a common issue.This was a bit of a pain of the job (front end off!) and after not getting the connecting plug seated properly and having to remove it twice.
On testing again it will idle for 30 minutes and checking on VCDS/VAGCOM the deviation value on injector 4 goes way out and then begins to misfire and stall and will take ages for it to restart again.
Strangely it has now been left waiting for the next stage for over a month which it has been started every day to move and never had issues
This has now been diagnosed as a faulty injector/s so I have purchased some replacements and after waiting for over a month now I am going to attempt replacing myself as all the mechanics I speak to are shying away from working on this engine.
What specialist tools do I need to remove the injectors and to realign and set them once replaced? How do I turn the engine over as their is no crankshaft pulley to turn as a normal cengine?

Thanks
 

·
Super Moderator
Joined
·
9,030 Posts
As said in your other post you need to check compression on all cylinders and also check block 004 in engine using vcds first and see what the cam timing is. Even though it's been fine for 32k the camwas out then and may have slipped and put the timing out further. You possibly haven't checked fuel pressure at idle like was suggested but have changed stuff which on line mechanics have suggested. The law of averages is eventually will find the problem but at what cost? Injector deviation goes out because the ecu is trying to stop the engine running away and keeps the rev's under control, it could be low compression caused by cylinder bore wear, vavles no seating correctly or one of the followers are damaged. If the front was off to do an injector loom which in my opinion isn't as unreliable as the 1.9 pd as the loom is not submerged in the oil. There was other stuff you could have checked whilst in there.
 

·
Registered
Joined
·
189 Posts
Discussion Starter #4
Sorry festa I am just doing what other local so called mechanics nearby have advised.
But I believe they have even less knowledge than even I have and have only tackled the PD1.9D.
I have no way of checking the compression or the fuel pressure but luckily the front end is still removed so I can delve further if you could advise?
Should I get a compression tester and fuel pressure guage and if so where do I purchase these and how do I use them?
What should the cam timing be on measuring block 004?
I agree about the injector loom as I tested this on removal and could find no fault.
Lastly it seems very strange that this will idle for 30 minutes and go way off on injector 4 then stall and refuse to start. But am I reading to far ahead?
I am really struggling as their are no reliable mechanics locally that have dealt with this type of engines and the ones that say they have are telling me lies.
I didn't want to have to do this myself as I realise the complexities of this beast and understand that if I do something it is going to leave this grounded for quiet some time.

Thanks
SC
 

·
Super Moderator
Joined
·
9,030 Posts
First things first ...start the van and plug in vcds, go to engine 02 and then go to measuring blocks. Go to measuring block 004 and post up here the picture if you can get a screen shot. It will give an idea of injection timing and camshaft timing. An m10 pressure gauge to 10 bar...there is a test point on the tandum pump which requires an m6 allen ley to remove the plug. Place the gauge in the hole and start the van. Get a reading at idle and one at above 2000 rpm and post back on here.
 

·
Registered
Joined
·
189 Posts
Discussion Starter #6
Will post a reply. Will not be able to get to my van till Monday now as locked away.
Cheers
 

·
Registered
Joined
·
189 Posts
Discussion Starter #7
OK here goes at tickover on measuring block 004 It reads:
798RPM 7.4BTDC Ignition Timing 7.1o KW Idle stabilzation -2.5oKW Idle stabilzation

I haven't managed to get a reading for the pump as I do not have a pressure tester yet.

Are you sure this couldn't be an injector issue as when previously tested the deviation value on number 4 goes way off after half an hour on tickover and then stalls?

Thanks
SC
 
1 - 8 of 8 Posts
Top