Club 80-90 Forums

Hello,

thanks for advice with fuel filter. Bought correct one, fitted it and shes starting nicely again.

BUT...I have a serious drop in performance since undergoing various jobs in the summer. All the belts were replaced along with the gaskets and seals. I had 4 new injectors, 3 glow plugs and 2 new injector pipes. Had real problems setting her up after and had to take it to diesel specialist. Left nearly £200 there and he told me turbo had enough boost and timing belt now set up correctly. He did say that in his opinion the valve seats are worn as there is lot of white smoke out of exhaust. I am getting a very rich smell in the van and can smell it outside too. None of this was problem before it went in for new belts etc, it would get up to 90mph at a push. I just got back from run and at one point I was doing 45mph flat out in 5th gear. He showed me that on top of fuel pump there is a rod that when the turbo blows into the diaphram, it opens a gate on the fuel pump. This is only opening halfway.

Am wondering if worn valve seats could cause such drastic loss in power or if it is that link rod. I cannot adjust the link rod anymore. Also wondering if it could be fuel/air mixture incorrect. Please help, I am getting close to losing it with this van and unless I sort it soon, am going to change the engine. Allready spend over £500.

Thanks

Hi,
I don't think valve seats would wear so quickly, and coincidentally at the time of other work being done, to cause such a dramatic loss of performance. If it starts well, you have good compression so most likely nothing wrong with valve seats. Deinitely sounds like a fuelling problem from what you describe, and related to the work done. There are probable clues in your post that may point to the problem:

1. "I had 4 new injectors" - are they the correct ones with correct pressures, new or recon, done by reputable company etc etc - you see what I'm getting at. Just one bad one not atomising properly (or at all) could give you poor running and white smoke (unburned fuel). Another thing to check - any "blow-by" the injectors? Any leaks, bubbles or chuffing noise coming up the side of an injector - they could have left a copper washer out or not seated the injectors properly. This would cause a loss of compression and the fuel would fail to ignite and come out the exhaust all white and smelly.

2. "timing belt now set up correctly" - why? What was wrong with it in the first place, and is it right now? Those symptoms could still point to incorrect pump timing.

Just a couple of thoughts before you throw away a good engine in desperation - hope it helps!

90mph 1.6 td

Thanks very much for info AJSIMMO.

I think you are right. Ever since those injectors were fitted,(Bosch New units from GSF parts)the problem began. If what you are saying is correct, either GSF sold me the wrong ones (they looked identical) or they were fitted incorrectly. I will check around injectors as you say and take it from there. The van was running so sweet before,did two runs to Santa Pod in it, London and even Belfast. Was unsure if the cambelt had been changed, so got it changed and one job turned into many. It certainly is producing lots of smelly white smoke and struggles on any incline. Really appreciate your time and thoughts.

DSA...it would pull 90mph if you wound it right up for couple minutes, unloaded, downhill, with a slight tailwind..

dsa wrote:90mph 1.6 td

An indicated 90mph is easy.
Mine will do a TomTomed 83mph.

If the LDA (thing on the pump you described) is not operating properly then the signal from the turbo wont be able to tell the pump to deliver more fuel. This could be a major source of the the lack of power. Extra Air without any extra fuel wont make you go any faster.

Has your fuel pump been timed up since the belts were done?
It could be that your pump isn't set right and needs more advance if you are getting white smoke.

Thanks V-Lux for your help.

Have verified injectors ordered are correct today and also confirmed they are fitted/seated correctly, so it appears they are not to blame..
But after some ringing round, it is clear that the LDA should be opening fully and not halfway as mine is. I have located second hand pump with LDA for £50 and am getting it fitted saturday at Volksworld in Lydd,Kent. He seems confident too that it is the root of the problem. I am no mechanic, but learning lots as I go. I am confident that the pump was set up correctly after the belts were fitted. It was done by Injector Developments in Canterbury, Kent and they are tip top as far as diesels go. It was him that first established the LDA was not opening at all and managed to get it to open halfway (which improved performance a tad).
This club is spot on for info. Really appreciate your time and expertise. Will update sat evening and am hoping its going well again without the white smelly smoke!

Replacing the LDA will sort out your power problems, but i would be surprised if it clears up the smoke though.

What does the smoke smell like? Burnt engine oil or has it got a diesely smell to it? is it white/grey or white/blue?

Titus A Duxass wrote:

dsa wrote:90mph 1.6 td

An indicated 90mph is easy.
Mine will do a TomTomed 83mph.

So will mine but if you drive a 1.6 td a t 90 mph your engine wont last very long

V-Lux,

Smoke is white/grey I think. Cant really decide if its oily of diesel smell, hard to say. Probably more diesel. Will get this guy Saturday to cast his beady eye over it. Thanks

Forgot to mention one other consideration, you've got new injectors with an old pump. If that pump is struggling a bit to make full pressure in it's old age, it will take slightly longer on each new injector to make sufficient pressure to fire it, thus making injection timing retarded. If this is the cause it would most likely be worse on tickover, and clear a bit when revving. I'd try advancing the pump a tad.
Have you had any joy with that 2nd hand pump?

BTW if it went so well before, why did you decide the injectors needed changing? Just a thought.

AJsimmo

thanks for thoughts. Was advised to change them to cure white smoke and one was making tapping sound. Its ok in all respects other than its gutless and chucking out enough smoke to warrant being pulled over by the cops.
Hoping this guy sat will be able to sort performance with this pump he has. Will put your thoughts to him re advancing pump with smoking issue.
Thanks again

Do you know what specs the place used to set your pump timing?

If they used the stock specs, then its probably set not been set to 1mm, which is the preferred amount of lift by most people.

See what happens on saturday, i reckon the LDA is going to put a smile back on your face at least.

E X C E L L E N T N E W S!!!!!!!!!!!!!!!!!!!!!!!!!
SHES ALL SORTED AND GOING LIKE A (1.6TD) TRAIN AGAIN!!!

John Goldsmith at Volksworld in Lydd is a proper old school VW mechanic.
He found cambelt was tooth out, changed fuel pump/LDA and timed her up perfectly and she fired up after much priming and sounded better than ever.
Still a little smoke but approx 80% less than before and no smell at all, but best of all, performance is back up by at least 50%(well its a 1.6td you know what I mean). On way to him, I was doing 35mph flat out on flat road and on way back I did 45 mph UP steep hill. So, the love is back, shes been treated to wash and me and my little girl went out for first trip in it since god only knows when. But look, you was top notch and am sure will bend your ear again in future. To anyone having similar problems, ring John at Volksworld on 01797 344619, hes got VW's all over the place, is very patient and really knows his stuff.

You watch gearbox will fall out now, its too good to be true!

Thanks to VLUX & AJSIMMO - SPOT ON

Great news, good to hear