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Discussion Starter · #1 ·
Hi there all you 1.9td experts!!

Urgent advice needed!!!

I'm really worried about my 1998 T4 1.9td :(:(:(

Jumped it it this morning to go off and do a job and it was a bit reluctant to start. It fired with the cold start pulled out and then ran. Drove off in it and immediately realised it was down on power pretty significantly???:(

Got it on the dual carriageway and it was a struggle to get it above 50MPH, whereas normally it will easily hit 75-80 MPH?


Things I should mention!

I have been running it on a veg oil (KTC) and diesel mix (approx 50/50) for the last month or so and have done about 1500 miles. I haven't changed the fuel filter yet! I read a post saying that when using veg oil/diesel mix that a new filter should be fitted after the first 500 miles?? Then I saw another post saying to change the fuel filter after 5000 miles? Which is it?


Could I have a seriously blocked filter? Would this cause the huge drop in power? Also the van seems to be smoking from the back, which it didn't do before. I have a spare new fuel filter so I will swap it over !

The current fuel filter has only been on for about 1800 miles. New glowplugs, oil and air filter about 800 miles ago!


HELP!!

Alpenweiss2
 

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Check timing Especially crank nose condition
If filter related I would expect a deterioration over time rather than all good then all bad
 

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check accelerator cable get somebody to press pedal to floor (engine off lol) and check that the throttle lever is going all the way to the stop. the cables go faulty sometimes.

also fo the cost of a filter id replace it, the veggie oil cleans all the dirt out of the tank so its recommended to change filter about 500 miles after you have started to use veg oil. after that just change it once a year.
 

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Discussion Starter · #4 ·
I fitted a new throttle cable only two months ago and it was a genuine VW part?

Also I have just swapped over the fuel filter and it is no better???:(

Seems to be making loads of smoke from the back now when I drive it??

Can't hear the turbo whistling any more...could it have failed?


Cheers Alpenweiss2
 

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yes could have, not familiar with the set up on this but can you take the air filter pipe off to get to the compressor end of the turbo see if the compressor wheel is turning smoothly.


check your air filter it aint blocked as well.
 

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Can't hear the turbo whistling any more...could it have failed?


Cheers Alpenweiss2
Agree it could have failed but still find it hard to believe all was ok when last driven and then bad the next time,Turbos fail over time unless a big problem occurs and only then while it is running,what can happen to a turbo while stationary.
still sounds timing related....well assuming the rest of fuel system ok ie pump and injectors not clogged/gummed by veggie fat oh and barring a serious leak
 

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When I was running one on a 50 50 mix, mine was a pig to start and run when the weather got bad. The Veg oild thickens in the cold. Especially didn't like the KTC gen modified oil even in good weather. I'd wack a load of straight diesel in and see what happens
 

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Discussion Starter · #8 ·
Agree it could have failed but still find it hard to believe all was ok when last driven and then bad the next time,Turbos fail over time unless a big problem occurs and only then while it is running,what can happen to a turbo while stationary.
still sounds timing related....well assuming the rest of fuel system ok ie pump and injectors not clogged/gummed by veggie fat oh and barring a serious leak

Well I spoke to Youngs VW in Wrotham the specialist that looks after our two Golf Gti Mk2's and the owner Nick reckoned that for the issue to happen so suddenly that the problem could possibly be that the timing has slipped??

He said the crank pulley could have come loose and damaged the keyway, thus affecting timing. Even with new glowplugs and only running on pure diesel, my van was always reluctant to start decently without the cold start lever pulled fully out?? And it always smoked on start up!


So maybe the timing has gone awol? Anyway have dropped the van off at the garage and they are going to check it out.

It smoked like hell on the 8 mile drive to the garage with constant greyish smoke and black smoke under hard acceleration!!:eek:

Alpenweiss2
 

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Yeah deffo agree with that , done a couple recently that were similar and they both had about half the crank sprocket key worn away.
The timing could be reset and the van started easily and would run and rev smoke free..........untill stopped then when restarted it would be back to a bugger to start and smokey as hell.
The only thing I can think it when setting it the crank sprocket is getting pulled in to place and then when stopped the "bounce back" against rotation causes the sprocket to slip back out of time.
Good luck at the garage and keep us informed.
 

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Discussion Starter · #10 ·
Just had a phone call from Youngs Garage where my van is getting a check over.

Apparently the fuel pump timing was slightly and the pin wouldn't line up with the engine at TDC, but the crank pulley and bolt were fine with no movement or wear to the key way. They have reset the timing for me so it is spot on.

The garage said that the timing being out wouldn't have caused a sudden loss of power as it hadn't slipped and the crankshaft pulley was fine. So they suspected a problem elsewhere and checked the turbo.

They said it seems as though it is reluctant to spin? They also said there was wear in the spindle. They reckon that the turbo could be the issue as it doesn't want to spin freely??? They said it should spin with the slightest blow on it however when the engine was not running the turbine needed some effort to turn it using a finger?

I also told them that my van has been using lots of oil and they said it could be escaping through worn turbo seal.
After freeing off the turbine they fired up the van and said there was no smoke and it was spinning freely again??

The garage has advised that I fit a new or reconditioned turbo.They have spoken to VW and a new turbo is £608 plus VAT!!:eek::eek::eek: The cheapest they can get one is £375 plus vat reconditioned :(

I am absolutely gutted! And I'm not sure what to do. I really can't afford a new turbo, plus labour costs to fit it!

The garage has also said that if the turbine is spinning again, I may get another few months out of it, but obviously oil loss is an issue?

They also said there appeared to be a very minor leak from the diesel pump,as it was wet underneath, but not noticeable when the engine is running?


Any suggestions? Can they do anything to repair the turbo?

GUTTED! Just in time for Christmas!!:(:(:(

On the positive side, at least my pump timing is now correct!

Alpenweiss2
 

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I had a my turbo fully reconditioned fot £175 plus VAT. It was at a place called Midland Turbo's I think. It was for the full overhaul too so you need to shop around by the sounds of things?

If you google search for Turbo repairs & ring em up you should save a few $$'s

Good luck with your van repairs
 

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Discussion Starter · #13 ·
Bit of an update!

Youngs Garage have reset my diesel pump timing and by fiddling with the turbo, it seems to be working again.

However they have advised me that the spindle is worn and oil could be escaping past the turbo seal. My van has been using a fair amount of oil so it seems a good guess that this is where it is going? The sudden loss of power was down to the turbo sticking. Ideally it needs to be replaced asap.

I nearly fainted when they told me how much a new turbo would cost from VW - £608 + VAT!!:eek:

Anyway, I told the garage they I would try an source a replacement and just pick the van up and pay for the work to reset the diesel pump timing.

Checked a few sources online and read some posts on here, to see that I needed a Garrett GT15 Turbocharger!!

Lo and behold I found this one on ebay and it was listed at £50 with no bids! A few late bids came in but I managed to get it for just over £130 including postage. BARGAIN...I think?? and brand new!! T:

Would I need the garage to fit this or is it straightforward? How easy/hard is it to swap over? I'm guessing seized bolts etc??

Really hope this cures the problem...Alpenweiss2
 

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Discussion Starter · #15 ·
if you ever lose power quick and blow smoke check the turbo hozes firstT:

Well I didn't lose power whilst driving! Basically drove the van on Friday and it was fine. Drove it again the next day and it was well down on power from the off! Garage are convinced my turbo is worn and sticking. By examining it they loosened it off, but they reckon that's where all my oil is disappearing! They have checked the hoses and reckon they are all fine.


Alpenweiss2
 

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Hi, check out a company called turboactive, they specialise in refurbished turbos. I've had a couple from them and had no problems. Think they charge around £250 for a 2.5 turbo. You'll need to take it off and quote the part code to them then they'll be able to tell you which one you need. Not a huge job to change a turbo just make sure it's primed with oil before you fire it up.
The number is 08449808780
 

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Can you take pics and talk me through what you do with turbo. thinking of changing mine and like you cash is tight so would like an idea of how much work it is. oh and i`ve got to left hands:D.
 

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Discussion Starter · #19 ·
Can you take pics and talk me through what you do with turbo. thinking of changing mine and like you cash is tight so would like an idea of how much work it is. oh and i`ve got to left hands:D.

I don't really know how to change it?? Was hoping that someone on here would be able to explain?

Doesn't seem to be much on the forum about turbos or how to replace them?

Alpenweiss2
 
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