Alh 5sp injectors swaped into auto car

[BOWZ]

Hey guys, Just picked up myself another project TDI. This one is a 01 Auto w/260k. Back story is Shop owner bought it to fix up and daily. Trans supposedly redone in the shop as they were putting a new head on it from timing belt snapping. Ended up having hard starts with lots of smoke tossed another pump in with same result. Lost interest and that's where my story starts.

After it fires, it will put out a smoke screen for less than a minute then go away and run just fine. I feel this is an injector sticking. I was wanting to replace my 01 5sp with some DLC1019 nozzles, this might have just bumped up that schedule. So question is can my larger .184 nozzles/injectors work in this auto that came with .158 nozzles/injectors from the factory. What will be the result, bump in power (even less time left for the auto) same MPG?

I rigged up a system to bypass everything from tank to pump to rule that out. Same thing. Have some Liqui Moly Diesel Purge coming in tomorrow that I plan on running through it. Still would love any input you guys have.


Thanks in advance guys. Here is the mintest 01 TDI in the rust belt...


Bowz

 

[UhOh]

Wonder if the shop checked out the pistons/rods after the carnage? Just slapping on a head isn't going to fix things if rods got bent. And bent rods = lowered compression = harder starting.

I put the injectors from my wife's 5spd (another set with DLC520s went in her car) in to the daughter's 01m wagon. It perked the wagon up. Don't recall it having much affect on smoke, but I ended up getting it tuned to ensure that it's optimized: it really hauls now, with only a stage 1 tune; just stomping down and not having to shift this car just cranks through the gears; it's got a slightly bigger turbo (100hp version- came that way from PO), so perhaps less smoke was because it's a slightly bigger turbo.

 

[dweisel]

Check the timing.

 

[BOWZ]

Wonder if the shop checked out the pistons/rods after the carnage? Just slapping on a head isn't going to fix things if rods got bent. And bent rods = lowered compression = harder starting.

I put the injectors from my wife's 5spd (another set with DLC520s went in her car) in to the daughter's 01m wagon. It perked the wagon up. Don't recall it having much affect on smoke, but I ended up getting it tuned to ensure that it's optimized: it really hauls now, with only a stage 1 tune; just stomping down and not having to shift this car just cranks through the gears; it's got a slightly bigger turbo (100hp version- came that way from PO), so perhaps less smoke was because it's a slightly bigger turbo.

I'm not positive if they did or not, from talking to him it sounds like the shop didn't spare any money, it was the owners car and he wrenched on it when he had down time. They specialized in foreign cars (obviously not diesel). I did ask if they did a compression test(I was worried about washing out a cyl with the stuck inj) he said they also tested that and it was 425 +/- 5 across the board. I might just retest it to make sure, once it fires off though it will start again no problem and runs fine down the road. Thanks for the info on the swap, did you have to modify the #3 wire connection? I keep forgetting to compare mine, I've just read that they are different.

Check the timing.

I haven't plugged in my VCDS yet but owner did describe(I asked where it intersected on the screen) that the timming was slightly advanced after they installed the 2nd pump. Once again I will verify, I just want to keep run time down to a minimum.

 

[Mavrick]

Compression test. Should have 450-550lbs on every cylinder. All numbers being pretty close..

 

[UhOh]

Compression test. Should have 450-550lbs on every cylinder. All numbers being pretty close..

At 425 +- 5 I'd think that it doesn't have bent rods.

From http://www.myturbodiesel.com/wiki/how-to-do-compression-test-on-vw-audi-tdi-engine-results/

VW compression for all 1.9L diesel non pumpe duse (ALH AHU,1Z) and pumpe duse engines (BEW)
New: 363-450 psi
Minimum limit: 276 psi
Max difference between cylinders: 73 psi

Note - it's normal to get readings of up to 500-550 psi on a TDI engine, this is considered normal. The specs above are on a new engine, after the engine is broken in you may see higher compression. Keep in mind that high altitude will lower compression test readings.
​

 

[jettawreck]

At 425 +- 5 I'd think that it doesn't have bent rods.

From http://www.myturbodiesel.com/wiki/how-to-do-compression-test-on-vw-audi-tdi-engine-results/

VW compression for all 1.9L diesel non pumpe duse (ALH AHU,1Z) and pumpe duse engines (BEW)
New: 363-450 psi
Minimum limit: 276 psi
Max difference between cylinders: 73 psi

Note - it's normal to get readings of up to 500-550 psi on a TDI engine, this is considered normal. The specs above are on a new engine, after the engine is broken in you may see higher compression. Keep in mind that high altitude will lower compression test readings.
​

Although the spec'ed "minimum limit" is way too low.

 

[UhOh]

Although the spec'ed "minimum limit" is way too low.

I totally agree. I'd never feel good about that kind of number. And, rather than a percentage difference they give a flat-rate of 73psi. If one had 349psi across all cylinders except one and that one is 276psi it is still considered in-spec. That's a 20% difference! I'd like to see VAG's engineering notes on this: are they figuring that the ECU is able to adjust for this?

 

[BOWZ]

Picked up the Moli-lube today along with 4 new inj crush washers. ran the cleaner for the sake of it, noticed that the inj pump is leaking on the 2nd seal down, I'll have to read up on replacing that seal. One thing i did notice was how aerated the return fuel was. is this normal? crazy, it'll take 30 sec cranking with tons of smoke and once it fires runs just fine. my 5sp injectors from my other TDI will be going in this weekend if weather plays nice. Thanks for the heads up on compression guys.




Bowz

 

[UhOh]

Is that inline filter on the right line? Never mind if this is just a close-up of how it's set up in in the first picture in this thread.

Can you identify what "Moli-lub" product you're using?

 

[wonneber]

I had the same thing in the return.
Car seemed a bit better, I was not impressed.
Ready to order injectors and want to do a purge first.

 

[BOWZ]

Is that inline filter on the right line? Never mind if this is just a close-up of how it's set up in in the first picture in this thread.

Can you identify what "Moli-lub" product you're using?

It is there diesel purge. Filter is on the inlet.

Bowz


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[jettawreck]

Lots of air in return line probably due to the leaking seal or a different air leak. The IP is a suction pump on the inlet portion and any leaks in the supply result in lots of air in the return.

 

[BOWZ]

I'm getting a seal kit tonight, thanks for the input. Have my manual injectors swapped into the auto, freed up the stuck waste gate. took her out and she ran like a top. We will see tomorrow morning if the hard smoky starts are gone. I can't get pictures loaded right now but I'll toss up a video and a picture of the nasty injector tips that came out of the manual.

Bowz

 

[BOWZ]

Well crank time is cut down to 10% of what it was. New fuel filter is going in today, going to check inj timming in the computer then the mechanical timming as I wait for the seal kit.

Sitting for 14 or so hrs.

http://s53.photobucket.com/user/big...B4E7BA90-89D0-4829-B970-5D7F7DD282B4.mp4.html

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[BOWZ]

Adjusted timing. So far advanced it was off the screen. Changed the fuel filter. I'm pretty sure the date was from 2006. Still hard starting. Going to do pump seal job when the parts get in this week. After that I suppose it's either compression test or possibly fuel supply(tank pickup)


In the mean time got to cracking on the other TDI.



Bowz


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[BOWZ]

Just tried starting it with a clear return line. Entire time it wouldn't fire the line was empty. I think the pump is leaking down. Anything in the tank for a check valve?


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[wonneber]

There is a check valve in the pickup that many drill out.
The Canada cars do not have it.