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TDI Conversions Discussions on converting non TDIs into TDIS. More general items can be answered better in other sections. This is ideal for issues that don't have an overlap and are very special to swaping engines.

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Old December 1st, 2019, 04:53   #106
jmodge
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Any idea how the mechanical timing became off the graph?
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Old December 1st, 2019, 11:16   #107
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I don't have a clue. The week before I changed quantity adjuster seals top and bottom. It ran fine other than the 4-5 rotations when starting in the morning. The timing was slightly advanced which is the way I set it. I changed the IP head seal Wednesday and timing way off. Unless losing the bolts moved the IP. They seem rather tight. Now the engine sounds louder and I have what seems like turbo lag. This morning it at least 5 rotations before engine started. It was 60 degrees outside. Did I pinch the seal. The main goal for installing the seal was to help eliminate having the engine rotate 4-6 rotations before starting. Anything I can test the vagcom to verify all is well? Also, not seeing air in the fuel line.
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Old December 1st, 2019, 19:19   #108
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I drove a short distance from the house and it shutoff. It appears the engine has seized. Will remove the valve cover tomorrow evening. First I going to remove the serpentine belt and check the alternator. The brake lights warning appeared shortley before the engine stalled.
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Old December 2nd, 2019, 19:30   #109
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Lifters are hosed. Pulling the heads sometimes tomorrow to see how the pistons look. How did changing the IP head seal throw off the timing? Maybe just a consequence. The hard morning starts. The timing belt was still firm. If not fixable may purchase new 1.9 engine.
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Old December 6th, 2019, 08:13   #110
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I removed the valve cover and 1 valve was destroyed. The others looked fine. Timing belt was tight appeared not to have jumped... I need to remove the head. I couldn't find a valve12MM TRIPLE SQUARE CYLINDER HEAD BOLT TOOL locally - autozone, etc. I ordered one online. Should be here Monday.
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Old December 11th, 2019, 15:48   #111
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Heads and Piston-
Still can't determine why there was interference. Sending heads to Frank.

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Old January 29th, 2020, 16:46   #112
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Frank rebuilt my head. He sent me a new timing belt tensioner stud but no nut. Is it ok to use the old nut or should I use a new one? I picked up some 8x 1.25 at autozone not sure they are same specs.


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Old February 12th, 2020, 05:41   #113
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something must have made the timing move, otherwise why would valve/piston contact result?
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Old February 24th, 2020, 08:44   #114
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No doubt timing moved... Anyhow, I completed timing belt installation. I quadruple check the timing to ensure timing is correct. I used coat hanger(removed glow plug), crankshaft and harmoic balancer to verify TDC. I wish while I had the heads removed. use the VW tool to place a mark on flywheel. Would make timing much easier... Where does this part go?


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Old April 2nd, 2020, 19:28   #115
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Truck running fine but taking to long to start. No doubt it is worse. Does not matter cold or hot. In the morning, if I turn on my inline fuel pump and let run for 2 minutes, it will start quick. From the tank to inlet of the fuel filter, fuel doesn't leak down (valve prevents fuel from leaking down to tank). It appears I'm losing prime at the injector pump. Not sure! I replaced the head seal on the injector pump about 2 months ago. It really has been an issue since installing the engine. Is the IP leaking down? No external leaks! Is it an injector? When I bought the car, it had been in a collision that knocked the lift pump bottom off. Later Motohead1 says 2002 vw 1.9 TDi did not come with a lift pump. I thinking they must had trouble starting and installed a lift pump. Looking at the VCDS, should all 4 cylinders specs be similar? Cylinder one is substantially lower than the other cylinder







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Old May 1st, 2020, 17:33   #116
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Default resolved slow starts!

Ever since I completed my swap I've had slow starts. I spent hours testing new fuels line, electric inline lift pump, etc., etc. When I installed the high torque starter, I dropped it cracking the plastic on the solenoid. Nothing appeared broke internally so I glued the plastic back and seemed ok other than slow starts meaning take 4-6 cranks to start. About 6 months ago, the two long starter bolts had become lose and one fell out. . I remove and took to local starter shop. They check it out and said starter was fine replacing the two bolts. Still same issue. Finally starter started dragging. I took it back and they solved the issue. Now the 1.9 starts blistering fast. The other day I checked my fuel mileage and getting 32 mpg around town. Not bad.
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