Posted this on the general Tech forum a couple of days ago but have had little response, hope the Alternative engine lads may have some info...
I'd guess that my problems have been answered many times but as a I'm new to this game I'd like to ask again.
I have a 1989 TD with a recently fitted rebuilt AAZ engine (fitted previous to purchase), for the first few weeks or so it seemed to start and run ok, although now it still runs ok and performance seems not to be affected it has developed a few annoying problems.
From a cold start the van is very good a providing a smoke screen, very good if you are been tailed but probably not if its the police!
This can be limited if acceleration is applied lightly and gears not shifted to early.
If the engine is not'caught' by the accelerator cold starting can be difficult, this would lead me to question the glow plugs? Its worth noting that waiting for the light to go out or using the cold start 'choke' have no affect!!
Once the van as been running for a while the smoke seems to reduce and the van motors and pulls pretty good, hills and acceleration not providing a problem!
So once on the move the next problem evolves when the rear window slowly gets darker.... investigation proved oil from the exhaust...?
Oh and also once we drop below 2000 RPM..... 'the buzzer of doom' says hello!
I've previously been told the problem may be turbo related and that the oil in the exhaust could be from damaged/warn turbo seals and this may also relate to glow plug damage which would relate to the cold start problem??
I've checked for oil 'blow' at the breather on top of the engine and nothing bad shows but would like confirmation for what I may be looking for?
I have not yet carried out an oil change so I don't exactly know how much oil I am carrying, I have tried to keep the level somewhere between the high and low marks, my dipstick is the same as a 1.6TD, is this correct for a 1.9TD AAZ engine?
Thanks for reading my post to the end, please provide me with some 'good' news.............!
Any help or suggestions would be appriciated. Ta
AAZ...cold starting & oily exhaust probs..where do i sta
Moderators: User administrators, Moderators
-
v-lux
- Trader
- Posts: 737
- Joined: 07 Aug 2006, 18:54
- 80-90 Mem No: 2951
- Location: Somerset....yarp!
- Contact:
Firstly and foremostly!
Drain all the oil from the engine, refill with precisely 4.5 litres, run engine, wait a bit, then check the level. This is the correct oil level for your engine ( as long as you dont have an aftermarket oil cooler) The JX dipstick may not have been modified correctly which could mean you have too much oil.
What colour is the smoke? Are we talking LOADS of smoke, or just a bit when you start it? How quickly does it settle down?
There are 2 senders for oil pressure, one that works above 2000rpm, another that works below. IIRC the one below 2000rpm is the one thats in the back of the block (towards front of van). Could be worth seeing if someone can check it out for you.
A pressure test might not go a miss either.
This is possible.
Worth checking that all your glow plugs are working, if theyre not working properly, this will definitely affect your cold start!
Hope it helps
I have not yet carried out an oil change so I don't exactly know how much oil I am carrying, I have tried to keep the level somewhere between the high and low marks, my dipstick is the same as a 1.6TD, is this correct for a 1.9TD AAZ engine?
Drain all the oil from the engine, refill with precisely 4.5 litres, run engine, wait a bit, then check the level. This is the correct oil level for your engine ( as long as you dont have an aftermarket oil cooler) The JX dipstick may not have been modified correctly which could mean you have too much oil.
From a cold start the van is very good a providing a smoke screen, very good if you are been tailed but probably not if its the police!
This can be limited if acceleration is applied lightly and gears not shifted to early.
If the engine is not'caught' by the accelerator cold starting can be difficult, this would lead me to question the glow plugs? Its worth noting that waiting for the light to go out or using the cold start 'choke' have no affect!!
What colour is the smoke? Are we talking LOADS of smoke, or just a bit when you start it? How quickly does it settle down?
Oh and also once we drop below 2000 RPM..... 'the buzzer of doom' says hello!
There are 2 senders for oil pressure, one that works above 2000rpm, another that works below. IIRC the one below 2000rpm is the one thats in the back of the block (towards front of van). Could be worth seeing if someone can check it out for you.
A pressure test might not go a miss either.
I've previously been told the problem may be turbo related and that the oil in the exhaust could be from damaged/warn turbo seals
This is possible.
may also relate to glow plug damage which would relate to the cold start problem??
Worth checking that all your glow plugs are working, if theyre not working properly, this will definitely affect your cold start!
Hope it helps
mine did the same! seals on turbo went big time on second day of a three week holiday 
lost 2l of oil in a few hundred miles 
happened on peage and due to heat /speed had done the bottom end in aswell as stuffing turbo. for rest of hols put 1l of oil in every 100 miles!!! as soon as it got warm buzzer cam on at tickover - just increased throttle stop 
you say recently fitted and before you bought it ? how many miles have you done since youve had it ? had oil 'level' problems ? oil loss ? have you changed the oil ? maybe previous owner/seller filled it up with Lucas 'glue' to keep oil pressure up while he was selling it ?
lost 2l of oil in a few hundred miles happened on peage and due to heat /speed had done the bottom end in aswell as stuffing turbo. for rest of hols put 1l of oil in every 100 miles!!! as soon as it got warm buzzer cam on at tickover - just increased throttle stop you say recently fitted and before you bought it ? how many miles have you done since youve had it ? had oil 'level' problems ? oil loss ? have you changed the oil ? maybe previous owner/seller filled it up with Lucas 'glue' to keep oil pressure up while he was selling it ?
AAZ cold starting
Sorry to join in on this, sundial, but I have similar problem, though not as bad. Also AAZ fitted by previous owner. On start from overnight stand engine starts from immediately but fires on three and blows blue smoke. Wife objects as I park near the washing. Settles down after about thirty seconds (engine, not wife) and then runs normally. Restarts with any difficulty during the day. Seems this only occurs after standing for at least six hours. I haven't worried about it much but winter approaches and I wonder about glow plugs. Trouble is they are sods to get at and I have been warned difficult to get out. I expect your AAZ is lying partially on its side - I wonder if this has any effect as the turbo is now right down the bottom. My engine oil is correct level. I will be interested to know how you get on.
Swallowtail
-
sundial
- Registered user
- Posts: 43
- Joined: 02 Jul 2007, 20:45
- 80-90 Mem No: 4778
- Location: Devon's Atlantic Coast...
Have replaced oil today with exactly the correct amount recommeded, this shows no more than about 4mm on the bottom of the dipstick , quite un-nerving if you didn't know how much oil you'd put in!!
Have run van around and still have oil blowing from the exhaust, this may be old oil left in the silencer as it's still black on the rear panel....I hope it is anyway!!
Van still smokes from a cold start, and will smoke intermittanley on a run...cannot yet conclude wether this relates to the old oil in the exhaust or wether there is a deeper problem!
'buzzer of doom' will still say hello when it decides!!
Only conclusion so far is that it appears the engine has been over filled at sometime as I took about 5 litres out when it was changed...!
Starting is still dificult unless the gas is pumped which causes more smoke.... I'll takle this when the smoke and oil problem is resolved, I'm sure it's all related.....somehow??
Have run van around and still have oil blowing from the exhaust, this may be old oil left in the silencer as it's still black on the rear panel....I hope it is anyway!!
Van still smokes from a cold start, and will smoke intermittanley on a run...cannot yet conclude wether this relates to the old oil in the exhaust or wether there is a deeper problem!
'buzzer of doom' will still say hello when it decides!!
Only conclusion so far is that it appears the engine has been over filled at sometime as I took about 5 litres out when it was changed...!
Starting is still dificult unless the gas is pumped which causes more smoke.... I'll takle this when the smoke and oil problem is resolved, I'm sure it's all related.....somehow??
-
sundial
- Registered user
- Posts: 43
- Joined: 02 Jul 2007, 20:45
- 80-90 Mem No: 4778
- Location: Devon's Atlantic Coast...
AAZ...cold starting & oily exhaust probs..where do i sta
Just in case post is still been followed.....
Oil changed a week ago to correct amount, have run engine in hope that oil still in exhaust system would eventually be blown out, have proven this to be not the case as the silencer has been removed and oil is still been blown out of the exhaust!!!
Although now I have decided to let someone have alook at the van, hopefully in a couple of weeks time, I would appreciate any idea's to where the oil is coming from ie. turbo or piston rings??
Would it be right to assume that if oil was getting thru the pistons the engine would run on using the oil as fuel when the ignition is switched off??
Cold starting and smoke not yet investigated, although i've justed had my starter motor rebuilt as the soleniod to motor wire had corroded so much it broke away at one end!!
Oil changed a week ago to correct amount, have run engine in hope that oil still in exhaust system would eventually be blown out, have proven this to be not the case as the silencer has been removed and oil is still been blown out of the exhaust!!!
Although now I have decided to let someone have alook at the van, hopefully in a couple of weeks time, I would appreciate any idea's to where the oil is coming from ie. turbo or piston rings??
Would it be right to assume that if oil was getting thru the pistons the engine would run on using the oil as fuel when the ignition is switched off??
Cold starting and smoke not yet investigated, although i've justed had my starter motor rebuilt as the soleniod to motor wire had corroded so much it broke away at one end!!
-
Westy.Club.Joker
- Registered user
- Posts: 484
- Joined: 18 Sep 2006, 19:37
- 80-90 Mem No: 2863
- Location: Sunny Lancs. 1988 1.6TD Westfalia Club Joker pop-top
Turbo is my guess, remove the turbo inlet pipe (the one from the air filter to the turbo) and check that side first, then remove exhaust pipe from the other side of the turbo, I would think you`ll be seeing fresh unburnt oil on that side. Check the impellor shaft both ends for any side to side play in the bearings, could just be blown seals if it`s not making a load whistling noise when boosting. Rebuild on the cards.
If it was the rings, or cracked piston, or anything internal in the engine it`d be burning the oil as fuel in the combustion and you`d be seeing blue smoke in the exhaust, not fresh oil coming through the system.
If it was the rings, or cracked piston, or anything internal in the engine it`d be burning the oil as fuel in the combustion and you`d be seeing blue smoke in the exhaust, not fresh oil coming through the system.
Keep it real.
Search first - ask second ;>}
Search first - ask second ;>}
-
HOT 1200
- Registered user
- Posts: 13
- Joined: 12 Jul 2007, 13:28
- 80-90 Mem No: 2233
- Location: Sun Rise Coast NORFOLK
Your not the fist person who has suffred the 'over filled with oil' syndrome.
Ive seen at least 3.........and each one ended up with a blown turbo.....one even swalled its own engine oil causing the engine to lock up ....it had nearly 6 litres of oil in the sump!!!!
I'll say it one more time........to help spread the word.....
The only true way to establish the correct MAX oil level on an aftermarket 1.9 TD or TDI install is to:-
Drain the oil
Remove the old oil filter
Fit new filter
(the correct Mann filter for a T25, you know the massive one that is bigger than Golf or Passat)
If you use a golf/passat oil filter which are smaller, then 4.5 litres will still be 1/3rd litre too much for T25 50deg engine angle.....
Fill with 4.5litres of oil.
Start engine, let it run for a couple minutes.
Switch off
Go make a cup of tea....come back, check oil level
This is your new 'Max/Full level'
Remark the dipstick !!!!
Then, if you have any sence, make a new dipstick to match the one above, only longer with a minimum mark too........!
If people continue use the AAZ dipstick and fill to the factory MAX you will have put nearly 5.5litres of oil in the motor......made worse by small Golf/Passat oil filter
Was that loud and clear enough????????
Ive seen at least 3.........and each one ended up with a blown turbo.....one even swalled its own engine oil causing the engine to lock up ....it had nearly 6 litres of oil in the sump!!!!
I'll say it one more time........to help spread the word.....
The only true way to establish the correct MAX oil level on an aftermarket 1.9 TD or TDI install is to:-
Drain the oil
Remove the old oil filter
Fit new filter
(the correct Mann filter for a T25, you know the massive one that is bigger than Golf or Passat)
If you use a golf/passat oil filter which are smaller, then 4.5 litres will still be 1/3rd litre too much for T25 50deg engine angle.....
Fill with 4.5litres of oil.
Start engine, let it run for a couple minutes.
Switch off
Go make a cup of tea....come back, check oil level
This is your new 'Max/Full level'
Remark the dipstick !!!!
Then, if you have any sence, make a new dipstick to match the one above, only longer with a minimum mark too........!
If people continue use the AAZ dipstick and fill to the factory MAX you will have put nearly 5.5litres of oil in the motor......made worse by small Golf/Passat oil filter
Was that loud and clear enough????????
-
sundial
- Registered user
- Posts: 43
- Joined: 02 Jul 2007, 20:45
- 80-90 Mem No: 4778
- Location: Devon's Atlantic Coast...
Many thanks for the replies, it is good to know that the turbo is the most likley suspect of my problem especially as the engine has been over filled, this sounds better than the alternative.
Unfortunatley the oil was over filled when I brought the van therefore I guess the damage may have already been started, as already stated I have the correct amount of oil in the engine now, although a little to late!!
The replacement filter I fitted is most likley a golf/passat filter, the one I took off was a MAN filter but is no bigger than the new one, where do I get the correct MAN filter from and what type of filter do I ask for?
Thanks
Unfortunatley the oil was over filled when I brought the van therefore I guess the damage may have already been started, as already stated I have the correct amount of oil in the engine now, although a little to late!!
The replacement filter I fitted is most likley a golf/passat filter, the one I took off was a MAN filter but is no bigger than the new one, where do I get the correct MAN filter from and what type of filter do I ask for?
Thanks