Tdijarhead
Top Post Dawg
- Joined
- Nov 10, 2013
- Location
- Lawrenceville PA
- TDI
- 2003 TDI Jetta Daughters Car, 2001 TDI Beetle, Wife’s car, 2005 Golf TDI Mine, all 5 spds
Several of you know that my daughters 01 Bug quit while she was driving. It restarted and sounded terrible. After troubleshooting I found the engine was in time and the turbo seemed good. I found the clutch had broken. The pics and story are here.
http://forums.tdiclub.com/showthread.php?t=506276
I got it all back together rechecked the timing and started it. It still sounds terrible. I began troubleshooting again. IQ, jumping around, cylinders at -1.88 or + 1.88 at the limit. Random misfire codes.
I checked the timing, it’s right against the upper line. I finally got the IQ around 4.5 but it is not steady. I checked for injector leaks, none. I swapped out a couple of injectors, they made no difference in either cylinder. I checked the #3 cylinder wiring and one of the injectors I swapped was the #3.
I shut it off rotated the engine to check the timing again and now I have a hard stop. So I loosened the belt, removed the cam to check the lifters smooth and shiny, some wear but no domes or spider cracks. The last three lobes of the cam closest to the vacuum pump show some chamfer wear so a new cam should probably be considered.
I reassembled and reset everything to TDC rotating the crank 1/2 a turn to lower the pistons and moved the cam and pump then I locked them and put the crank back to TDC also. After all this I tried turning the engine by hand and it still is up against a hard stop.
Have I forgotten something or do I have a valve in a cylinder? Before I pulled the head I thought I would ask and see if anyone had a similar experience. If I have a valve in a cylinder how did that happen when I have no evidence of valve piston contact in the cam?
http://forums.tdiclub.com/showthread.php?t=506276
I got it all back together rechecked the timing and started it. It still sounds terrible. I began troubleshooting again. IQ, jumping around, cylinders at -1.88 or + 1.88 at the limit. Random misfire codes.
I checked the timing, it’s right against the upper line. I finally got the IQ around 4.5 but it is not steady. I checked for injector leaks, none. I swapped out a couple of injectors, they made no difference in either cylinder. I checked the #3 cylinder wiring and one of the injectors I swapped was the #3.
I shut it off rotated the engine to check the timing again and now I have a hard stop. So I loosened the belt, removed the cam to check the lifters smooth and shiny, some wear but no domes or spider cracks. The last three lobes of the cam closest to the vacuum pump show some chamfer wear so a new cam should probably be considered.
I reassembled and reset everything to TDC rotating the crank 1/2 a turn to lower the pistons and moved the cam and pump then I locked them and put the crank back to TDC also. After all this I tried turning the engine by hand and it still is up against a hard stop.
Have I forgotten something or do I have a valve in a cylinder? Before I pulled the head I thought I would ask and see if anyone had a similar experience. If I have a valve in a cylinder how did that happen when I have no evidence of valve piston contact in the cam?