Reconditioning diesel engines

[peter_j_g]

Interesting how this topic has digressed! I agree with comments about genuine/non-genuine, I try to stick to OEM or genuine. Also checking the VW dealer price is often a good idea, although they don't carry much for 25 year old golfs anymore!

But back to the topic....

I've wired the glow plugs to the battery so I can operate them manually, and also connected the stop solenoid to the battery. I think these two eliminate any electrical problems, however still no go!

I've read on an american web site about priming the fuel pump with ATF - anyone tried this?

Thanks!

[imported_brackie]

ATF

Atf won't hurt your pump in the short term. However.... what reason do you have to believe there's no diesel in the pump body? You said that you are getting diesel at the injectors at turnover. This wouldn't happen if the pump was full of air. I'm beginning to think that the problem may lie in fuel supply. There should be a clear plastic hose from your fuel filter to the pump. Are there air bubbles in this? How long since you put in a new filter? When the motor turns over does it fire at all? If you need to prime the pump you must do it by putting clean diesel into the outlet banjo. Alternatively, you can suck diesel through the pump by applying a vacuum to the same. Have you tried tow starting the car?

[peter_j_g]

I think I've eliminated the electrical side of things, so I'm turning my attention back to the fuel. I am getting some fuel at the injectors - but maybe it's not enough? My fuel line isn't clear plastic, it's solid rubber, so I can't see if there are air bubbles. I have a non-standard CAV filter system, which first has a glass bowl water trap where the fuel filter normally goes, and then a CAV fuel filter by the windscreen washer bottle.

I'll try a new filter, current one has served around 3,000km, and I'll also get a new primary filter that sits in the fuel tank.

It's uphill from my garage to the road, and not many big hills around, but will try towing if I'm still stuck!

Thanks again - I'll post when I have an update...

[imported_brackie]

H2O?

Don't suppose water could have got in during the recent wet weather? Drop the glass bowl and see what you get out. (Water doesn't combust too well!) I'm still not convinced it's low compression that's the culprit. I've had engines on their last legs that would still start. I'd strongly recommend clear plastic lines both in and out of the filter. You can see straight away if there's any air. The primary fillter in the tank can cause problems. Hopefully you don't have any fungi growing in there! I had that problem back in WA and had to clean the tank and the whole system out. Black, gooey stuff.

[gldgti]

i've had a similar problem with mine on occasions, which was always resolved by tow starting.

I use an aftermarket (i imagine all of you wincing) filter, with 2 - count em - 2 little clear plastic $2 filters that you get from a box at supercheap auto. the 2 filters go infront of the main filter to get rid of any nasties before they go and clog up my nice $20 dollar filter

the 2 plastic ones are in parallel too - this slows the flow rate so that water, black gooey crud and other non fuel deposites dont actually get stuck in the filter - they sit in the bottom of the plastic housing where you can look at em.

anyway, if you've ruled out electrical problems, then definately give it a good prime and try a tow start. you can also try loosening the injector lines to rid each line of air - air bubbles seem to like to stay present and often air will be immovable trapped in the solid lines. you just back off a couple of the lines at a time by a turn or tow (so they are actually loose.) when you crank it you should find fuel dribbling out allover your injectors (ahh well, never mind the mess)

good luck

aydan

[Golf Loon]

Yeah I`ve pushed untold golfs up and down roads, only to have them start immediately with a tow start. Get a friend and some rope and you`re set!

[imported_brackie]

Agreed

Towing and using high revs by (perhaps) dropping her into 2nd, should get her going. The extra revs generate a bit of heat which always helps and builds up fuel pressure. This should purge any air left in the pump and lines. Can't remember any diesel that I've done major work on that I haven't tow started.

[peter_j_g]

Hi all,

Well folks I finally had the time to have another go at getting the Golf going. Towed it up the drive, then down the street to a small hill. Wife & eldest son pushing, wait till the speed got to 40km/h, 2nd gear, glow plugs on, then let out the clutch and ..... booom!!!! Away she went almost instantly! Huge cloud of smoke, but it settled down after 1km or so. Drove around a little bit, enjoying the mobility, then back home. Washed the car, it started normally, went to the nearby service station and filled it up. Started normally, then back home, stopped on the driveway and swept out the garage, then tried to start again. No go. Motor spins over fast enough but just won't quite fire. Enough for today, will try again later...

Maybe I need to move house to the top of a big long hill!!!

[peter_j_g]

Following on from the last post - Curiousity got the better of me, so I had to try it again - this time it started after turning over a few times! Let's see if it starts in the morning...

Has anyone tried a fuel additive/cleaner? I've used wynns diesel injector cleaner on occasions. Any brand better than another? Thanks!

[syncro]

Hi all,

Well folks I finally had the time to have another go at getting the Golf going. Towed it up the drive, then down the street to a small hill. Wife & eldest son pushing, wait till the speed got to 40km/h, 2nd gear, glow plugs on, then let out the clutch and ..... booom!!!! Away she went almost instantly! Huge cloud of smoke, but it settled down after 1km or so. Drove around a little bit, enjoying the mobility, then back home. Washed the car, it started normally, went to the nearby service station and filled it up. Started normally, then back home, stopped on the driveway and swept out the garage, then tried to start again. No go. Motor spins over fast enough but just won't quite fire. Enough for today, will try again later...

Maybe I need to move house to the top of a big long hill!!!

Have you uprated your starter cable and earth yet?

[peter_j_g]

Hi "syncro",

Interesting comment, I've noticed that both the starter and earth cables get very warm when cranking the engine. Does uprating the cables make a big difference? What size cable should I go for?

Thanks!

[imported_brackie]

Absolutely!

Earth cables were always a weak point. Go to Supercheap and buy a suitable length cable. Bolt it to the neg terminal and then to any of the bolts on the passenger side engine mount. You will be amazed at the difference! (However, I have a feeling that your glow plug relay could be playing up. It often results in an intermittent fault like the one that you are experiencing.)

[DOHCDAVE]

Peter you asked about fuel additive try FUEL DOCTOR it's green liquid in a clear bottle know the guy personly he's local to bris used it in the truck i was driving blew lots of smoke until started using fuel doctor got more klm's and generaly ran with a little more power. 1 bottle will last for a while as it recommends to give it a shock dose then about 25ml per tank.
Check out their web site think it is fueldoctors.com.au read up on it he showed me 6 or 7 different brands that sit alongside it on the shelf at supercheap and proved to me that it was the better of them takes to long to explain it to you guys but check the site out don't know how much info is there. But what the hell go and get a bottle and try it to the doctors recommendations and you should notice a diff.
Anyhow just a thought
cheers Dave

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[syncro]

Interesting comment, I've noticed that both the starter and earth cables get very warm when cranking the engine. Does uprating the cables make a big difference? What size cable should I go for?

When you try to start with the starter, you are drawing a very high current. The higher current the higher the voltage drop, the less heat in the glow plugs and speed of the starter. The starter cable and the earth straps are far too small on a Golf Diesel and most of the old GLDs that I have seen were modified years ago.

You can run multiple earth cables to the engine and starter mounting bolts and just get a thicker cable for the battery to starter cable.

[imported_brackie]

Interesting comment, I've noticed that both the starter and earth cables get very warm when cranking the engine. Does uprating the cables make a big difference? What size cable should I go for?

You can run multiple earth cables to the engine and starter mounting bolts and just get a thicker cable for the battery to starter cable.

Yeah...Starter bolts are a better option, You can't get much closer than that!