very lumpy start, lots of blue smoke, no power at low rev

[Tommy000]

Hi,

I have just had another 1.9td AAZ engine installed in my t25 after the last one cooked due to all the water leaking from the system. when the engine was changed, all the ancillaries had to be removed from the old engine and put on to the replacement engine. They also advised that new glow plugs were fitted as the previous ones were knackered.

When you start it up, full choke [as normal] , the glow light doesn't to go out and after about a minute or two, turn the key and it starts on first turn. The glow light can stay on for a while, almost it feels until the chambers get warmer and they are not doing the trick. its very lumpy as if only firing on 2/3 cylinders, almost unresponsive to the throuttle to begin with. if I don't give it any throttle from first start, the engine will just cut out after a minute or so. as soon as you give it revs, the smoking starts, quite a lot in my view... its blue and there is a lot... Once the engine has warmed up a bit, its more responsive to the throttle and the lumpyness has gone, no sign of missing or smoke. When you try to pull away, the power is so low that I have only tried to start it on a gradient once, the one try, a 10 foot hill was going to defeat me, but it just crawled up. Until the revs get up, the power is really not there and if I get into 4th gear, unless I am above 45-50 its almost unresponsive to increases in throttle.

If I stop for a short while, it starts up fine, but the engine can literally but totally unresponsive to throttle movement for a short period of time and the power at low revs is worse than before. Once running and keeping the revs up, it seems to be fine and as I would expect.

I did speak to mechanic regarding the engine replacement and he said to be very conscious of the fuel pump being changed as they need a specialised knowledge to get them right and some of the symptoms above sound similar to what he described if its not set up correctly.

thank you for any help, advise or maybe a shoulder to cry on :-[

[Smcknighty]

Did you pay someone to do it?? Your saying even when's it's warmed up it drives crap?sounds like they didn't set the fuel pump up properly? It's not that hard if it's the same principles as the 1.6 and I believe it is. Glow plugs wise - they should either go off in temperature being hit or a time period by default. On the 1.6 it's 60 seconds. I don't think they stay on post start though

[ajsimmo]

Did they swap the pump from one engine to the other, or did the replacement AAZ come with it's own pump? Sounds like the pump and/or cam timing is out, but they're not hard to do. Any competent mechanic can do it with some simple tools (cam locking kit and a dti).

[T25Bluealloy]

sounds like my engine, i have an old 1994 AAZ 1,9 TD CL passat engine and its on its way out, thick blue smoke then it goes to black every time i change gear, i am lucky if i get 55 out of it, however it has done over 140,000 miles and my glow plug light stays on for over 1min as well... is yours second hand?