Diesel Engine 1.6TD help.

Post by **Fully Loaded Cali'** » 17 Sep 2007, 17:15

I have a 1.6TD (westy California) that i have owned for a month now. I feel it is seriously under powered, i know that these engines are not known for theier power but this is NO power!

I think the problem is around the turbo. I have removed all the covers from under the engine and found that the turbo is a brand new unit, problem is that all the pipes going to it are knackered!!

The large plastic pipe from the air filter to turbo is broken where the rubber oil pipe connects, causing big oil leak. I've ordered a new one. Would this pipe affect the turbo performance??

The short rubber pipe from the cylinder head to turbo (large dia) is in very poor condition but i can't see any holes in it, if i hold this pipe and rev the engine i would expect to feel it expand, it does not.

There is a unit mounted on top of the engine on the fuel pump system next to the accelerator linkage. It has a plunger / rod whick looks like it operates by a vacuum, the only thing i have seen that looks like this is on a twin choke carb, when the first choke opens fully then this plunger pulls the rod and opens the second choke - hence more power. Does this unit do the same thing - how can i check if it workin?? I have tried revving the engine but it does not move.

I think there is some operation in the turbo as when i accelerate i can here a faint whistle / wheeze from the engine.

The main problem of lack of power is from first gear into second, no matter how fast i change gear, the revs drop and there is no power, the van struggles to pull. If i am on a hill then i got no chance. Once into second the change into third is a breeze with power available.

If anyone manages to read to this stage, thanks and any thoughts would be appreciated.

P.S anyone know of a good Diesel engine mechanic in the West Midlands??

Post by **syncroandy** » 17 Sep 2007, 18:30

No quick answers for you I'm afraid, just a point about boost. The turbo will not produce any under no-load, so if the vehicle is just sat in neutral and you rev the engine no pressure will be produced.

The unit on top of the fuel pump is the LDA, which creates some enrichment under boost (hence the narrow rubber hose to the inlet manifold).

The 'oil leak' from the cracked turbo air inlet tube is just the oil spray/vapour venting out the engine breather and being recycled. A lot of this would indicate excessive blow-by = worn-out engine.

The first thing to do is get your engine and pump timing checked. Then get your valve clearances checked (they have solid lifters with shims, which may need adjusting). Turbo boost can easily be checked with a gauge.

Post by **Fully Loaded Cali'** » 17 Sep 2007, 18:40

Thanks for reply. There is A LOT of oil leaking from the cracked pipe, about an egg cup (only thing i could think of!!) full on the floor when i stop.

Oh, another problem, i have a diesel leak from this linkage, dripping onto the block on tick over, is there a kit available to fix, or do i need a new unit??

The engine itself looks like it has been re-built, it has 222000 km on the clock but every nut and bolt and all the top pipes are brand new, there is evidence of at least a topend re-build but unfortunately i have no history.

Post by **syncroandy** » 17 Sep 2007, 18:55

That seems a lot of oil, the level is correct is it ? Leaks from the fuel pump are almost certainly bad news, you might just try checking the banjo bolts for the inlet and outlet are OK (tight and with copper washers).

Post by **Fully Loaded Cali'** » 17 Sep 2007, 20:20

The leak is from the actual end joint of this plunger to the cam type mech on the pump unit (if that makes sense). If i put my fingers on this connection when the engine is running, they are wet with diesel, after a few secs it drips.

The oil leak - i used 6ltrs of oil on a trip to Newquay in cornwall from Wolverhampton, prob did around 800miles.

Van does smoke (as friends have told me) but i thought it was the way i was thrashing it to make it move!! I have just sold a '65 split camper that had a 1500cc single port. That had used to fly (and no smoke) even fully loaded. Who in VW put these engines in these vans?? I would have sacked him / her!!!

Post by **Westy.Club.Joker** » 17 Sep 2007, 20:30

I would be contacting the seller. I know he gives you all that old bo**ox about "no warranty" etc, but as a dealer he has to provide something that is "fit for the purpose" and the engine is obviously knacked and badly worn. 6Ltr of oil in 800 miles is defo not normal, and if it leaked that much you`d know about it (and it would be all over your tailgate, which it obviously isn`t, as being white it would show up

)

(posted by the bloke in the big hat at Vanfest)

Post by **Fully Loaded Cali'** » 17 Sep 2007, 20:47

Hello Westy Club Joker! Hope u had a good Van Fest!! I would take it back to the dealer but more bother than it is worth springs to mind (at this stage). I will soon get a full diagnosis on the motor, and if ANYTHING should be found that was ok'd by the seller, then that will be nasty. It will be took further and everyone can watch

(only after his one chance of defence of coarse).
I had an issue with my rear brakes, they were actually bolted to the back plates!!!! instead of the bar and spring, this has been photographed and witnessed, just as further back up.

Just need the van to go up hill without the smoke and hazards flashing.

Post by **colinMSC** » 18 Sep 2007, 14:39

using that much oil is not good , but i would be thinking the turbo was at fault firstly, if it were badly worn rings she would not start up at all. as diesels require good compressions for it to run.

Post by **ELVIS** » 18 Sep 2007, 16:46

my engine uses/ed 1 litre every 100 miles - needless to say ive just got in after spending the day in my garage taking the old one out ready for the AAZ.
has no pressure when hot at tick over ( does yours idle quite quickly - check seller hasnt upped the idle to hide low pressure at tick over) my turbo is abosolutely dead - loadsa play in spindles and exhaust turbine dripping with oil - have you checked yours just hasnt been cleaned or maybe rebuilt by a mong with a home repair kit and its still shagged. good luck

Post by **Fully Loaded Cali'** » 18 Sep 2007, 18:57

Turbo is definetely new. New casting, new briaded hoses and the manufactures steel lable pinned the side.

The oil is coming from the main air pipe where a branch leads off to the smaller rubber pipe that leads back up to the rocker cover.

It's the no boost thats puzzling me. I think i need a mechanic to positively tell me if it is working or not, cos if it is, then engine will be coming out!!!

Post by **Andyvandy** » 18 Sep 2007, 19:34

Hi,

I would recommend you get someone to fit you a 1.9TD AAZ engine from a Golf etc.

I have a Westfalia California too, which the previous owner had fitted the 1.9TD as a replacement for the worn out 1.6TD.

With this engine it flies! It has great acceleration (partly due to being undergeared as the gearbox is the original one)

There is a guy in North Wales, I don't remember his name he is around on the forum. He quoted me around £1000 to fit an AAZ engine in my old 1.6D Westy.

Hope you get sorted

Andy

Post by **ELVIS** » 18 Sep 2007, 20:00

i would go back to chodder who sold it ya , 1 month and its duff

Post by **shepster** » 19 Sep 2007, 07:30

ELVIS wrote:i would go back to chodder who sold it ya , 1 month and its duff

ABSOLUTELY!!!!

Post by **HOT 1200** » 19 Sep 2007, 13:24

"There is a unit mounted on top of the engine on the fuel pump system next to the accelerator linkage. It has a plunger / rod"

Hi, the rod is your 'cold starting aid' you should see a 'choke' cable connected to a lever, this is then connected to a rod. All this does is advance the pump timing by 2deg and increase residual fuel quantity at idle......its just helps you start during cold mornings....
Sounds daft, but have you checked tyre pressure, brakes binding etc....
They are all signs for power zapping problems at slow speeds (i.e between 1st & 2nd gear changes)
Seems odd that you have power through the higher gears....??
I would change all the boost hoses if your not happy with there condition/apprearance.....
GaV

Post by **ELVIS** » 19 Sep 2007, 20:00

HOT1200 - after reading his previous posts i think he has probs finding 1 +2 due to fecked gearleaver/linkage and brakes arnt binding as they were non existant - as i say , chodder feckin gets it anyway you look at it !!!! you can end up throwing good money after bad forever otherwise