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South Eastern USA Local discussions for those in the South Eastern USA. (Alabama, Florida, Kentucky, Georgia, Mississippi, North Carolina, South Carolina, Tennessee)

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Old May 20th, 2009, 09:23   #1
DanG144
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Default Doin's at Dan's

Someone is usually doing something at my place - it seems about half the weekends, or so. Just in case anyone wishes to drop by and shoot the breeze (or help) I thought I would start this thread. I have been sending PMs to those I thought my be interested, but thought I would try this instead. If anyone wishes to drop by PM me for directions and contact info (unless you already have it).

Saturday and Sunday May 30, 31 2009. Working in the shop on a 98 New Beetle Gasser. Waiting parts on UG's car.

Andreigbs and I are planning to inspect his cam, clean and inspect his fuel pump, and do a TB job on his BEW this Sunday (5/24/2009) starting about 0800.

I have Ugly Greasanova's car in the shop checking out hard/no starting, as well. (http://forums.tdiclub.com/showthread...72#post2563472) So far I have found that the main fuel tank is full of varnish (at least that is what it looks and smells like - marine varnish or linseed oil - dark brown with a slight odor) instead of dino diesel. The fuel filter appears to be plugged slightly - it takes about 8-10" of mercury vacuum to pull fuel rather than 4-5" Hg - and I am getting a whole lot of entrained air (continuous bubbles) as well. I plan to clean out the main fuel tank, put in another fuel filter, clean the fuel pickup unit and drill it out, then see if it will draw fuel normally, with no entrained air.

UG's car did start when a positive pressure feed of dino diesel was supplied.

I am a bit concerned since the timing is showing severely retarded (UG's ALH); has it skipped a tooth on the timing belt? I will be checking this evening.



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Last edited by DanG144; May 29th, 2009 at 18:12.
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Old May 20th, 2009, 10:11   #2
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Hey Dan I 'll try to drop by on Friday. I drove the '09 to CLT yesterday and experienced the dreaded CBEA hiccup but so far in 3 tanks (1500 miles) we're averaging 43mpg. Seems like UG's car is succumbing to it's diet of grease would hate to think what the stresses the IP is enduring.
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Old May 20th, 2009, 11:07   #3
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In the Bio-diesel crowd a varnish smell indicates bacterial growth in the veg-oil. Commonly associated with moisture in the oil or processed fuel.
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Old May 20th, 2009, 13:21   #4
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sounds like UG need a good bio-cide treatment
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Old May 20th, 2009, 18:12   #5
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Default Update on Ugly Greasanova's ALH Jetta

I could not check the timing on UG's car because the greasecar system covers the timing mark window.

The timing belt is shredding along the outside edges and the teeth are deformed on the inside edge. But there is no evidence of missing teeth or skipped teeth.

The car has been running - I checked the timing after it was warmed up last night and it was severely retarded. It would start ok once it was warmed up on dino fuel.

The belt is bad enough in appearance to give me concern about continued operation. I'll try to get some photos posted.

[IMG][/IMG]

[IMG][/IMG]

I am not sure you can see this very well, but the teeth along the back of the belt are crushed and damaged. Very strange.
[IMG][/IMG]

Last edited by DanG144; May 20th, 2009 at 18:56.
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Old May 20th, 2009, 18:45   #6
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[IMG][/IMG]


[IMG][/IMG]

The belt is looking pretty bad.
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Old May 20th, 2009, 20:32   #7
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Ouch! TB RIGHT NOW! Look for whatever is slicing and dicing the belt.
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Old May 21st, 2009, 03:36   #8
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My best guess right now is that fuel is leaking out the injector pump shaft seal, softening and dissolving the belt.

I will keep looking for mechanical interference, but have found none yet.

Pretty spectacular.
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Old May 21st, 2009, 03:40   #9
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wow, good find!
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Old May 21st, 2009, 06:02   #10
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Hey Dan, there is some good info in this thread on IP's

http://forums.tdiclub.com/showthread.php?t=245955
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Old May 21st, 2009, 18:34   #11
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Hey dan is the belt tensioner loosening up???
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Old May 21st, 2009, 19:01   #12
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The TB tensioner on UG's car is still right in the middle of the target window.
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Old May 21st, 2009, 19:08   #13
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Man, those pix are UGLY. UG has the right handle, all right.
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Old May 22nd, 2009, 13:21   #14
DanG144
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Default update on Ugly Greasanova's car

The timing belt seems to have jumped a tooth. The photo below is the timing mark shown with the pin in the injector pump and the cam plate installed.

No wonder VCDS showed "timing severely retarded".

It seems to have skipped only one tooth, and the cam and IP are still in time with each other - just out of time with the crank by one tooth. The car still runs, though it takes about 10 seconds of cranking to fire.

[IMG][/IMG]

As for the leaking IP shaft seal, I asked MTBR (Steve in Fort Worth) for some advice. It was well worth the PM. Steve suggested sending the IP to a re-sealing specialist. For $165 (plus shipping) he will replace all the seals in the IP. UG may well want to pay this rather than have he and I learn on his IP. His IP was performing well - no other issues.

So UG is reviewing his options. $50 in parts and tools from Dieselgeek (and two rookies learning on his IP, and potentially at his ultimate expense), about $200 for the expert resealing, or $500-$1,300 for DFIS to refurbish completely.
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Old May 23rd, 2009, 05:52   #15
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Pictures of UG's fuel pickup assembly. It was originally built as a "C" model, then altered to be an "H" model. This was apparently done by some vendor, as it now has a paste on label that says it is an "H" model. UG says it has only been in service "a very short time."

[IMG][/IMG] This is the inner fuel pickup canister. Note the sediment, some of which looks as if it is granular. Since this fuel had to go through the VO fuel filter, I am postulating that this is a precipitate of some sort. Or else the filter is blown through?

The fuel system seems to have had a control failure such that recirc flow always went to the dino fuel tank, even when it should have been going to the VO fuel tank.

[IMG][/IMG] This is a photo of the outer fuel pickup canister. It is much cleaner. None of this stuff was in the main fuel tank (no sediment or crystals), it all settled in the fuel canister, which is where the return fuel is dumped.
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