[Vwdiesel] Remember bad starting man.

[decker at toledotel.com]

Hi Iain:
    The pump is the easy one to fix. I know you will probably cuss me before
you are done but you can fix the pump without taking it off. Since the cold
start valve is on the engine side of the pump there is very little room to
maneuver. I used a small right angle screwdriver and perhaps a needle nose
vice-grips to get the two machine screws out. If you look at the outside of
the pump opposite the cold start valve you will see a cover with two screws.
I just dispensed with the cold start rod and cover and used a solid cover
from the opposite side of another pump I had laying around. The cold start
valve only functions to advance the timing at low speeds to make the engine
run smother. I haven't had a cold start valve working for a couple of years.
When you get the cold start cover and shaft off you will see there is an O
ring on the shaft and another that seals the cover. I would go to a truck
diesel engine shop and I'm sure they would have such. Here in the States one
would look for a Cummins or Caterpillar engine dealer. Put the thing back
together just 2 screws and you have saved big bucks. Shouldn't take but an
hour or so to get it off and back on plus whatever time it takes to go to
town and locate a couple of O rings.

    My 1.6 N/A 1981 Dasher had gotten so it would start but almost
immediately die. I had to glow and start it two or three times when cold. I
replaced the fuel filter and that didn't help but still felt it was a fuel
delivery problem so I put a full can of Diesel-Purge in the fuel tank and
now it starts like it should. Replacing a tank is a good thing. They are
prone to leak where the fuel line comes out when they get old.
Brian Decker
Western Washington
----- Original Message ----- 
From: "Iain Hunter" <sagspottery at tiscali.co.uk>
To: "VWfans" <vwdiesel at vwfans.com>
Sent: Saturday, November 29, 2008 10:05 AM
Subject: [Vwdiesel] Remember bad starting man.


Remember me. Iain, with the T3 1.6 TD that wouldn't run.

Well a month later, and the problem is still not sorted. I changed the
plugs, and tested they were getting hot, which they were. I checked the
filter was free of water, I advanced the pump, and all number of other small
checks, but still had the same problem.
Last week I decided to have it towed around to a local garage to see if they
could diagnose the fault. The mechanic said that he was sure it was the
tank, as when he ran it off a Gerry can directly to the pump, it fired up OK
and the fuel-line/ tank junction had rusted through to virtually nothing and
it was probably sucking air. (I had to take his word for this as it was
something I hadn't checked, but I have known him for a while). So he ordered
a new tank, fitted it and I picked it up that night, running fine. The next
day, it wouldn't start again and had exactly the same symptoms - stuttering,
running lumpy and cutting out after about 30 seconds - so I got the guy back
round. It was at this point that I noticed a pool of diesel underneath the
pump that had not been there before. It looks like it is dripping from the
cold-start spindle, and according to the mechanic, this is going to cost
big-time. Now, it looks as though I might have to pay for a tank and fitting
that didn't really need replacing, and the garage mechanic that I trusted
seems to be losing my confidence by the second.
According to said mechanic, a pump expert could service the pump at around
£50 per hour???
I already have to replace a leaky exhaust manifold gasket and a leaky oil
return pipe from the turbo, which were going to be my next jobs. This could
mean having the manifold skimmed, as I think it could be warped, and if the
bolts don't come from the head easily, then it could turn really nasty.
I am fairly new to diesel engines, and although I can do some jobs myself, I
am beginning to think it would be cheaper to stick-in a used engine.
Would a straight swap for a later 1.9TD or D be a viable alternative to
loads of small, costly repairs? I am beginning to think a straight diesel
might be better, as there is less to go wrong.

Any thoughts would be greatly appreciated.

Iain.

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