DanG144
Top Post Dawg
Well, it is now firmed up.
January 28, 2012 will be the winter GTG at my house.
January 28, 2012 will be the winter GTG at my house.
Doin's at Dan's
- Thread starter DanG144
- Start date
DanG144
Top Post Dawg
I seem to remember someone with a Common Rail engine needing a timing belt soon - but I have forgotten who it was.
Anyone in the area need a CR timing belt done in the near future?
Anyone in the area need a CR timing belt done in the near future?
DidJettarun
Veteran Member
John Peacock is close as I recall
DanG144
Top Post Dawg
Common Rail Timing Belt replacement notes tips
Just did John's timing belt a week ago. Common Rail engine. Not really any startling difference from an ALH.
I did take great pains to ensure the fuel system was refilled - as it was emptied partially by the TB work, then even more by filter replacement. I ran the lift pump a couple of times, then both the lift and aux pumps three times.
http://www.contitech.de/pages/produk...cial_01_en.pdf for Contitech's instructions. It leaves off a lot of the interference removal.
Some notes I made:
Penciled in to my Bentley A5 service manual section 15b.
page 9 exploded drawing - bolt 17 should say "always replace" Large roller bolt.
page 9 exploded drawing - bolt #28 vibration dampener bolts, there is only about 2 threads of these bolts not embedded in the crank pulley, so when I tightened them 90 degrees they felt as if they were getting very weak. So I removed one - it came loose very easily (I think it was severely overstretched) it seemed much easier to remove than when initially taking the car apart. I replaced all four bolts (used new bolts each time) and this time only turned them an additional 45 degrees. Violate the tech manual instructions at your own risk. This is just what I did.
Page 10, I removed the fuel filter squeeze clips where the underhood lines meet the under car lines, took the bolts out of the fuel canister mount, and rotated the whole assembly up and over the top of the engine, leaving the fuel lines on the aux pump and HPFP intact.
Page 10 I did not remove the intake air duct.
Page 11 I did not have to remove the ribbed belt tensioner - a pleasant surprise.
page 11 I did not have to remove any coolant pipe brackets.
Page 12 I did not have to losen any coolant bracket bolts.
Page 14 Remove both Cam and HPFP rig pins prior to rolling the engine two turns.
Page 15 specified Clockwise rotation.
Page 16. Note that the cam and HPFP bolts are finally tightened an extra quarter turn. I only tightened them to 20 Nm when rolling the engine by hand initially - only when everything was just right did I do the extra 90 degrees. The extra 90 degrees tightening means that these bolts must be replaced each time.
Page 17 run the lift pump via output test 2x for 30 seconds, then run both the lift and aux pumps 3x for 30 seconds via basic settings 35.
Some photos are at https://docs.google.com/?tab=mo&auth...U1ZjkxNzYwZjYz
Just did John's timing belt a week ago. Common Rail engine. Not really any startling difference from an ALH.
I did take great pains to ensure the fuel system was refilled - as it was emptied partially by the TB work, then even more by filter replacement. I ran the lift pump a couple of times, then both the lift and aux pumps three times.
http://www.contitech.de/pages/produk...cial_01_en.pdf for Contitech's instructions. It leaves off a lot of the interference removal.
Some notes I made:
Penciled in to my Bentley A5 service manual section 15b.
page 9 exploded drawing - bolt 17 should say "always replace" Large roller bolt.
page 9 exploded drawing - bolt #28 vibration dampener bolts, there is only about 2 threads of these bolts not embedded in the crank pulley, so when I tightened them 90 degrees they felt as if they were getting very weak. So I removed one - it came loose very easily (I think it was severely overstretched) it seemed much easier to remove than when initially taking the car apart. I replaced all four bolts (used new bolts each time) and this time only turned them an additional 45 degrees. Violate the tech manual instructions at your own risk. This is just what I did.
Page 10, I removed the fuel filter squeeze clips where the underhood lines meet the under car lines, took the bolts out of the fuel canister mount, and rotated the whole assembly up and over the top of the engine, leaving the fuel lines on the aux pump and HPFP intact.
Page 10 I did not remove the intake air duct.
Page 11 I did not have to remove the ribbed belt tensioner - a pleasant surprise.
page 11 I did not have to remove any coolant pipe brackets.
Page 12 I did not have to losen any coolant bracket bolts.
Page 14 Remove both Cam and HPFP rig pins prior to rolling the engine two turns.
Page 15 specified Clockwise rotation.
Page 16. Note that the cam and HPFP bolts are finally tightened an extra quarter turn. I only tightened them to 20 Nm when rolling the engine by hand initially - only when everything was just right did I do the extra 90 degrees. The extra 90 degrees tightening means that these bolts must be replaced each time.
Page 17 run the lift pump via output test 2x for 30 seconds, then run both the lift and aux pumps 3x for 30 seconds via basic settings 35.
Some photos are at https://docs.google.com/?tab=mo&auth...U1ZjkxNzYwZjYz
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DanG144
Top Post Dawg
An ALH will be in the shop on Monday 1/2/2012.
I will be working around the house tomorrow and Monday.
Call or drop by if you need anything.
I will be working around the house tomorrow and Monday.
Call or drop by if you need anything.
ecodean
Veteran Member
Dan, I just sent you a PM about possible work on my car. Let me know what you think.
Dean
Dean
03PlatinumTDI
Veteran Member
Thank you GREATLY Dan for your help. You have once again made the ole' Jetta better than she was. See you at the GTG.
DanG144
Top Post Dawg
You are welcome, Peter.
TerryTDI (ALH) is limping in from Charleston today. Power supply issues; car would not run. No glow plug, no CEL, fuses are good. He tried a new 109 relay - no help. I had him put a jumper onto his fuel cutoff solenoid, this back powered the ECU and allowed the car to run.
NewbeeMC9 (ALH) is pulling his car down from the Upstate today, suspected blown headgasket.
TerryTDI (ALH) is limping in from Charleston today. Power supply issues; car would not run. No glow plug, no CEL, fuses are good. He tried a new 109 relay - no help. I had him put a jumper onto his fuel cutoff solenoid, this back powered the ECU and allowed the car to run.
NewbeeMC9 (ALH) is pulling his car down from the Upstate today, suspected blown headgasket.
terrydtdi
Veteran Member
Problem Solved!
Well I needed to get to Dan's so he could take a look see. Dan suggested I use a jumper wire going from the positive post on the battery to the injection pump solenoid, which fed power back to the ECU. I was able to drive 123 miles.
Going back to what I had going on, no Glow Plug light, or Check Engne light showing on the dash as the key was turned. NO start! I tried a spare 109 relay I had ( brand new), and it didn't change anything.
Dan checked power going to the fuse panel on all engine related fuses, everything appeared to be good.
Dan also had a spare 109 so we decided to try it, and wala! The moral of this story, just because it's new doesn't mean it works.
I purchased the extra 109 the year after I purchased my car for this reason, and it didn't work.
After further scans we found out the Check Engine light is burnt out on the dash. Glow plug light was working fine.
Dan is the best! Thank you Dan
Well I needed to get to Dan's so he could take a look see. Dan suggested I use a jumper wire going from the positive post on the battery to the injection pump solenoid, which fed power back to the ECU. I was able to drive 123 miles.
Going back to what I had going on, no Glow Plug light, or Check Engne light showing on the dash as the key was turned. NO start! I tried a spare 109 relay I had ( brand new), and it didn't change anything.
Dan checked power going to the fuse panel on all engine related fuses, everything appeared to be good.
Dan also had a spare 109 so we decided to try it, and wala! The moral of this story, just because it's new doesn't mean it works.
I purchased the extra 109 the year after I purchased my car for this reason, and it didn't work.After further scans we found out the Check Engine light is burnt out on the dash. Glow plug light was working fine.
Dan is the best! Thank you Dan
whitedog
Veteran Member
Yes, he is.
dirtysouthjacket
Veteran Member
Thanks again Dan for letting me use the shop and lift Saturday. Got the shocks, struts, LCA bushings, and dogbone all replaced. Also, the ESC light cleared on its own after two starts. Looking forward to the GTG! Thanks again as always!
Also, I am very interested in the wheels on the parts car you have. Let me know if you are still willing to sell them.
Also, I am very interested in the wheels on the parts car you have. Let me know if you are still willing to sell them.
CinRG
Veteran Member
1/28 gtg
Dan - going to try to make this. Can u post ur address, start/end time, other details, etc.
DanG144
Top Post Dawg
Check out this thread
http://forums.tdiclub.com/showthread.php?t=336805
There is a google document in the first post.
One of the tabs on that document has directions, contact info.
I am free giving it out, but I do not want it posted openly on the 'net.
http://forums.tdiclub.com/showthread.php?t=336805
There is a google document in the first post.
One of the tabs on that document has directions, contact info.
I am free giving it out, but I do not want it posted openly on the 'net.
DanG144
Top Post Dawg
There is one deployed serviceman's family bringing an 06 Jetta BRM around for a checkout Friday. Needs a TB and perhaps other services.
Then midnTDI is coming by Friday evening. We will spend Saturday and Sunday morning working on his ALH Jetta.
Things will be a bit slow over the next month as we prepare for my son (Zeb's) upcoming nuptial celebration.
Then midnTDI is coming by Friday evening. We will spend Saturday and Sunday morning working on his ALH Jetta.
Things will be a bit slow over the next month as we prepare for my son (Zeb's) upcoming nuptial celebration.
Elfnmagik
Veteran Member
Congrats!
Robert6401
Veteran Member
Thank you so much, Dan. And congratulations on the upcoming celebration!
DanG144
Top Post Dawg
You are welcome.
My weekend guests left today (back to the Submarine base in Norfolk) with a new timing belt, brake flush, 2.5" exhaust system, transmission fluid change, and a few parts he scavenged of the 2005 wreck.
I found a broken glow plug, an NGK 7V steel sheathed ceramic in a BRM engine. The steel sheath covers only half the length of the ceramic. About .2" of the tip broke off about 600km ago.
The engine appears to have suffered no damage from this, which is not always the case. The injector balance is fine and the turbo still seems ok.
This is, I believe, the third case I have heard of the BRM ceramic plug breaking off in the last few months.
My weekend guests left today (back to the Submarine base in Norfolk) with a new timing belt, brake flush, 2.5" exhaust system, transmission fluid change, and a few parts he scavenged of the 2005 wreck.
I found a broken glow plug, an NGK 7V steel sheathed ceramic in a BRM engine. The steel sheath covers only half the length of the ceramic. About .2" of the tip broke off about 600km ago.
The engine appears to have suffered no damage from this, which is not always the case. The injector balance is fine and the turbo still seems ok.
This is, I believe, the third case I have heard of the BRM ceramic plug breaking off in the last few months.
DanG144
Top Post Dawg
Working on a BRM TB and cam replacement, and a few other minor tasks this weekend. The owner is a deployed serviceman.
Robert6401
Veteran Member
Hey Dan, first of all, thanks again!
If you have time to send me updates I'd love to hear how it's going.
If you have time to send me updates I'd love to hear how it's going.
DanG144
Top Post Dawg
Interferences removed. Down to the TB itself, so I can do the cam and TB.
The fuel filter was so clogged that it would not drain; I pulled the filter out of the canister and carried it the drain can - and the center plenum of the filter was still full of fuel - it could not gravity drain back out. You could not have been getting full power fuel flow through it.
I cuss the lack of coolant drains on the later TDI's every time I work on them. The Mk V and VI are the worst so far. I need to measure the bottom hose and cut it to install a drain in it, for cars that I will work on again. Coolant drains for the block would be nice, too.
Did you ever decide about the wheel "locking" bolts? You want them reinstalled or replaced?
Also Jeff sent your ECU back Next day freight - it came in today. Chances are good your car will be ready to pick up Sunday.
The fuel filter was so clogged that it would not drain; I pulled the filter out of the canister and carried it the drain can - and the center plenum of the filter was still full of fuel - it could not gravity drain back out. You could not have been getting full power fuel flow through it.
I cuss the lack of coolant drains on the later TDI's every time I work on them. The Mk V and VI are the worst so far. I need to measure the bottom hose and cut it to install a drain in it, for cars that I will work on again. Coolant drains for the block would be nice, too.
Did you ever decide about the wheel "locking" bolts? You want them reinstalled or replaced?
Also Jeff sent your ECU back Next day freight - it came in today. Chances are good your car will be ready to pick up Sunday.
Robert6401
Veteran Member
Dan, you are a true gentleman.
I'm sorry to hear about the fuel filter, I hope it didn't add too much hassle to the repairs.
The wife did mention to me that you talked to her about the locking wheel bolts, but I don't really remember what exactly the issue was. If it's not something that needs to be replaced, I'd say not to worry about it. You are already doing so much.
I am very happy to hear that everything is ahead of what you had anticipated, but wifey will be even more pleased to know she may be able to stop driving the MkII sooner. Let me know when to send her your way.
I'm sorry to hear about the fuel filter, I hope it didn't add too much hassle to the repairs.
The wife did mention to me that you talked to her about the locking wheel bolts, but I don't really remember what exactly the issue was. If it's not something that needs to be replaced, I'd say not to worry about it. You are already doing so much.
I am very happy to hear that everything is ahead of what you had anticipated, but wifey will be even more pleased to know she may be able to stop driving the MkII sooner. Let me know when to send her your way.
DanG144
Top Post Dawg
New cam, followers, cam bearings, cap bolts, cam seal, rocker bolts installed.
The only issue with the locking bolts is that many times the tool gets lost, or it is in the trunk under tons of vacation luggage when you need it. I have spare bolts around, and can replace them with standard bolts at no cost. It does depend on where you park it. If you think the splined bolts are needed as a wheel theft deterrent, leave them in place. If not I would replace them with standard.
The fuel filter (all filters) were being replaced anyway (that was part of the parts price I quoted you.) So it was no trouble. But I have never seen one that plugged before. The filter media was actually deformed from high differential pressure; you see that a lot on the oil filters on these BRMs, but I have never seen it on the fuel filter before.
Thank Jeff Robertson (Rocketchip Tuning), too, for the chance to get the car back this weekend. I only paid him for standard shipping, and it did not leave here until Tuesday afternoon. He not only had to turn it around quickly, he had to be thoughtful enough to use US MAIL overnight, so that it would be delivered on Saturday. The mail lady drove up the drive and honked for me to come out of the shopt to get it.
Time for a nap, before finishing up the TB.
The only issue with the locking bolts is that many times the tool gets lost, or it is in the trunk under tons of vacation luggage when you need it. I have spare bolts around, and can replace them with standard bolts at no cost. It does depend on where you park it. If you think the splined bolts are needed as a wheel theft deterrent, leave them in place. If not I would replace them with standard.
The fuel filter (all filters) were being replaced anyway (that was part of the parts price I quoted you.) So it was no trouble. But I have never seen one that plugged before. The filter media was actually deformed from high differential pressure; you see that a lot on the oil filters on these BRMs, but I have never seen it on the fuel filter before.
Thank Jeff Robertson (Rocketchip Tuning), too, for the chance to get the car back this weekend. I only paid him for standard shipping, and it did not leave here until Tuesday afternoon. He not only had to turn it around quickly, he had to be thoughtful enough to use US MAIL overnight, so that it would be delivered on Saturday. The mail lady drove up the drive and honked for me to come out of the shopt to get it.
Time for a nap, before finishing up the TB.
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DanG144
Top Post Dawg
Finished up the TB, much of the interferences reinstalled.
Did some EGR system work. That part is ready to run.
Time to remove and repair the small fan.
Then reinstall the serpentine belt and tensioner.
Glow plug replacement and Glow plug harness replacement still to do.
Oil and filter change, 30 minute break in run, oil and filter change - 500 miles or so on this batch.
Still have to reinstall the ECU (RC1+ on it.)
Still looks good to finish up Sunday evening.
Did some EGR system work. That part is ready to run.
Time to remove and repair the small fan.
Then reinstall the serpentine belt and tensioner.
Glow plug replacement and Glow plug harness replacement still to do.
Oil and filter change, 30 minute break in run, oil and filter change - 500 miles or so on this batch.
Still have to reinstall the ECU (RC1+ on it.)
Still looks good to finish up Sunday evening.
Robert6401
Veteran Member
Wifey is very excited, going to see if Mak is available to take her to Chapin.
I don't see any real need for the locking bolts, but I'm assuming we have the tool. If so, I'd rather be safe than sorry and just leave it as is.
It sure doesn't sound like the PO took very good care of the maintenance aspect of the car. All the more reason I'm glad to have you giving it a fresh start. Now I can have peace of mind with wifey commuting in it.
I will find some contact info for Jeff and send my gratitude his way as well.
Email me or call her and let us know when she should come by.
THANK YOU!
I don't see any real need for the locking bolts, but I'm assuming we have the tool. If so, I'd rather be safe than sorry and just leave it as is.
It sure doesn't sound like the PO took very good care of the maintenance aspect of the car. All the more reason I'm glad to have you giving it a fresh start. Now I can have peace of mind with wifey commuting in it.
I will find some contact info for Jeff and send my gratitude his way as well.
Email me or call her and let us know when she should come by.
THANK YOU!
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Robert6401
Veteran Member
Email sent to Jeff
DanG144
Top Post Dawg
Adjusted the turbo vane stop, to hopefully cure the low power hesitation. That is a real pain to get access to. I had to remove the oil drain line.
The TB is in, the glow plugs have been replaced (but not the harness, yet.)
Still need to do the fan repair, break in run, and glow plug harness replacement.
Since I had a message from Bob saying that it is probably going to be Wednesday or later for pickup, I'll take a Sunday afternoon nap.
The TB is in, the glow plugs have been replaced (but not the harness, yet.)
Still need to do the fan repair, break in run, and glow plug harness replacement.
Since I had a message from Bob saying that it is probably going to be Wednesday or later for pickup, I'll take a Sunday afternoon nap.
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Elfnmagik
Veteran Member
Well earned it sounds like.
whitedog
Veteran Member
Nah. He's just old.
DanG144
Top Post Dawg
For now, considering the alternatives, I'll take getting older.
It'll happen to you, as well, you know, 'dog.
Changed the oil, did the break in run, changed the oil again.
It'll happen to you, as well, you know, 'dog.
Changed the oil, did the break in run, changed the oil again.