Rebuild next step: sorting the engine

lisab4

Veteran Member
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Oct 20, 2013
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Belgium
TDI
1996 Passat B4 1.9 TDI
So I'm 3 years into my complete rebuild
See main topic here: http://forums.tdiclub.com/showthread.php?t=443211



I am now going to try to sort the engine first. Replaced all I could, rebuilt head,... It starts at first try every time! Haven't run it more then a few minutes at once. However some issues:


*1 fault code:
01262 - Solenoid Valve for Boost Pressure Control (N75)
31-10 - Open or Short to Ground - Intermittent


* Yellow glows light stays on. Last months it started flashing, now it just stays on.


* I hear a knock coming from the belt side. Don't know if you can hear it in this movie? https://www.youtube.com/watch?v=cc518PXe4rY


*Also noted this: rubber deposit on the metal roller.


Any tips more then welcome :)
 

lisab4

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Belgium
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1996 Passat B4 1.9 TDI
Anyone? Especially the yellow glow light and deposit on the roller
 

jhax

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Jan 24, 2012
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Golden, CO
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96 Passat B4V, ALH engine out of a 2002 Jetta, some IE Rods and ASV Pistons. Nothing drivable yet though
The deposit may be chemicals left over post belt manufacture.
 

Steve Addy

Top Post Dawg
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Aug 7, 2002
Location
Iowa
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97 Mk3
Anyone? Especially the yellow glow light and deposit on the roller
I've had some belt deposits on the roller before but nothing like that.

It looks like a new timing belt? Is that true or has that timing belt installed for a while?

Steve
 

lisab4

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1996 Passat B4 1.9 TDI
have installed a new N75 which seems to have solved a power engine, and it runs smoother. Haven't yet read the codes to see if the code is gone.

Removed the residue from the roller. I'll see if it stays away.


Glow light still remains on :/ No idea as for the cause.
 

Yblocker

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Oakland, CA
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1997 Passat
I've listened to the engine vid a couple of times now, and I think it sounds like lifters. Where did you source the cam and lifters? Have you tried using a stethescope or long screwdriver to attempt to isolate?
 

ToddA1

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'96 B4V, '97 B4 (sold), '97 Jetta (scrapped)
Doesn’t the GP light also indicate an issue with the brake lamp circuit?

I’ve seen residue on the idler roller, but that’s after a decent amount of mileage. Did you use an off brand belt?

The codes will likely need to be cleared with VCDS.

-Todd
 

lisab4

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Belgium
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Yblocker, here's another vid of the knocking. I had the head rebuilt by a shop. No idea as to lifters.
https://www.youtube.com/watch?v=dwW8Y_qyg5A
Have not used a stethoscope.

Todd, Indeed used an off brand belt. It came recommended by the shop. I cleaned the roller, and it seems to stay clean now.
I will look into the brake lamp thing, thanks for the tip!
 

Windex

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Cambridge
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05 B5V 01E FRF
"off brand belt"

Yeeks! :eek:

I would look into the exact manufacture - Gates, Continental are both trusted and last the required duration.

Too many horror stories out there about wrecked heads with cheap chinese timing belts.

Can you say the total length of time the engine has run since started after the rebuild?

Not out of the ordinary for lifters to tap-tap-tap for many minutes after first start until they fill up with warmer lower-viscosity oil.

I would also find out the source of the lifters too... :D
 

lisab4

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I trust the shop that rebuild the head and got me the parts. They do work for my official VW dealer when it's too much for them. Really nice owner and a wealth of knowledge.
Gaskets were Victor Reinz. Think the belt might be too. I'd need to check
Total time run since first start, I think 15 minutes max.
 

Windex

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05 B5V 01E FRF
Interesting. It's hard to discern clacking noises on a diesel in a video, as they clack normally.

If I were in front of the car, I would want to use a stethoscope to isolate the noise and see if it's coming from the valve cover.

Failing that, I would remove the cam cover and depress each of the lifters (rotating the crank/cam if needed) with a wooden stick to see if any are spongy. They should not compress if they are filling with oil properly. If they do spring down and back up, then you have a lifter that is faulty or hasn't filled with oil yet.

Has the car been brought up to operating temperature and revved higher than idle for any period of time?
 

lisab4

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1996 Passat B4 1.9 TDI
Checked the belt. Brand is SKF
Windex, no it has not. It has only been idled, and been driven half a mile from the garage to my home at very slow speed. Never reached operating temp as I didn't dare running it for long with the glow light that stays on.
 

Yblocker

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1997 Passat
Checked the belt. Brand is SKF
Windex, no it has not. It has only been idled, and been driven half a mile from the garage to my home at very slow speed. Never reached operating temp as I didn't dare running it for long with the glow light that stays on.
Right. As Windix implies, before any further investigation into the noise issue, try getting the car really warmed up with some sustained higher revs- like for a good 30 minutes. I realize the car may not be ready for that, but when it is, that's what I would try first to see if those lifters pump up solid.
 

ToddA1

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'96 B4V, '97 B4 (sold), '97 Jetta (scrapped)
I remember just setting the lifters upside down, then filling them and letting them sit overnight was the way to bleed them.

The oil reaching operating temperature will definitely be better, but I don’t think it’s needed.

-Todd
 

Windex

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05 B5V 01E FRF
Not out of the ordinary for new lifters to take time to pump up.

Best technique is to bring the engine oil to temperature and raise the idle to 200 rpm or so. Thinner oil at higher pressure will pump up stubborn lifters. Suspect your tapping noise is just that - a lifter or two waiting to fill with oil.

SKF is a bearing company - I would look into who made the belt for them.
 

ToddA1

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'96 B4V, '97 B4 (sold), '97 Jetta (scrapped)
Lisa, I took a look at my wagon’s idler and it also has belt residue on it. The TB job was recently done, and other than idling to set timing, I’ve logged .5 to 1 mile of driving around the neighborhood.

My belt is a Continental.

-Todd
 

lisab4

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*The belt residue is gone. Cleaned it and doesn't come back.
* ticking noise remains
* N75 fault fixed (installed new one)

* reason I don't dare running it for long: That damn yellow light remains on!


I have reset the brake and cruise control switch. Both work. I have no engine fault codes coming up. And still. When I start, the glow light shines brightly. After start, it dims, but remains on.

Doe anyone have any clue about that light? I am stumped and frankly after 4 years of restoration and almost 20 grand, I just want the car to work :(
 
Last edited:

jhax

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96 Passat B4V, ALH engine out of a 2002 Jetta, some IE Rods and ASV Pistons. Nothing drivable yet though
I wonder if it's grounding out somewhere, my mk2 diesel has an ever so slightly always on glow plug LED.
 

ToddA1

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'96 B4V, '97 B4 (sold), '97 Jetta (scrapped)
If the GP light wasn’t lit before, and the wiring was good, it’s likely in the cluster.

A few years ago, I pulled a JY cluster and the oil pressure light would stay barely lit (only visible when it was very dark). Moving the cluster to a different car, it did the same thing. Installed a known good cluster in both cars and the oil light functioned properly.

That loose testing process pointed to the cluster.

-Todd
 

lisab4

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Thanks Todd! It's a converted MFA cluster. I'll try again with the original cluster.
 

lisab4

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Tried the original cluster, no problem. So it's the new MFA cluster that has a problem. I've e-mailed Derek at Chubs.
 

ToddA1

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Glad to hear that you found the issue, but sorry to hear that is a converted cluster.

Nobody in Europe, does this type of stuff? I can’t imagine shipping both ways, being cheap.

-Todd
 

Steve Addy

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Location
Iowa
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97 Mk3
Hope you get the cluster situation resolved. I have yet to install my cluster that I got back earlier, I should do that soon so I can see whether it functions properly.

With the available number of B4 parts cars declining I really wish I would have captured all the B4 clusters at the JY I worked at back in 2015. When those went to the shredder there were a lot of things, had I been thinking, I would have captured for the group here.

Steve
 

lisab4

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Shipping won't be cheap indeed. But it has to be done. It's off to Derek next week for repair. Hopefully that will be the last technical issue.
 

Chris_TDI_98

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1998 Jetta TDI 1.9L mk3 1Z AHU
Its probably just a leakage of light from a nearby light that’s on. You said the GP light glowed brightly (that’s when the GP light is on), then it went dim (that’s when light is leaking to there from a nearby light).
 

garciapiano

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Have you checked injection quantity and timing? I had a similar sound on mine after I did the TB but it was much quieter and went away after I sorted my mechanical timing and IQ.
 

lisab4

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1996 Passat B4 1.9 TDI
Didn't have time to work on the car the last months, gave it another shot today.
First start goes well, after that it's hard to start. It's running very rough. It also smokes a lot (grey) and when I gave it a little throttle, it nearly stalled.
Most concerning to me is that the ticking is getting louder. I've also seen that the camshaft has play in it. I see the bolt from the camshaft gear move when the engine is running. it is noticeably going up and down. I'm ready to drag it of to a specialist shop :(
 
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