Hi gents I'm after a bit of help with my 03 1.9 sdi.it's been regularly serviced and has just had cam belt and service.I was having cold start trouble so I had the glow plugs changed as well.this made no difference.it spins over fine and starts to fire and gathers pace until it runs proper.followed by a cloud of light smoke. If I let it run for 30seconds and turn it off and then start it again it fires straight up first turn? But if I leave it 3+hours I have trouble and the smoke? If I am driving here and there it will start up first time everything once you get it going.

I thought the diesel was going back down the pipe back to the filter so I fitted a non return valve in the line but this made no diffdifference.but when I cut the line hardly any fuel came out?

Any ideas chaps?

Have you changed the relay under the dash above the pedals I think its marked 103 its for the glow plugs or the fuel pump and is known to go faulty. cheers - Stuart

Edited 27 April, 201511 yr by sparky2

Hi Stuart. I did wonder about the relay but if that was faulty would the glow plug light still work?

i have taken out the relay for inspection and gave the terminals a good clean and put it back. upon first start up today when it was cooler i heard the realy swithing off and it started a bit better but not as good as it should and there was still a medium cloud of bluey grey smoke? im beginning to think it could have something to do with the fuel pump timing?Bearing in mind when its warm it fires up first time and with no smoke at all? i took of the cam belt cover to have a look around and noticed the three side bolts that look like they adjust the pump pulley have been moved at some point as you can see a previous position of the bolts due to an outline in the dirt?

Also a thing i did notice was the glow plug light is only coming on for two seconds and then going off? that seems a bit quick?

If you're only having problems with it firing first thing, it could be an air leak in the fuel lines from pump to injectors.

 

The glowplug light timing sounds about right for these engines since you're heating the combustion chamber and not an injection swirl pot. In fact, the glowplugs aren't cycled above about 5C anyway.

thanks ken, i just had a quick look over the pump and pipes etc and all looks ok except when i moved the black fuel return pipe on the right hand injector, the long one that goes back to the pump. it hissed a bubbled out a liitle bit of fuel so i pulled it off and put a small jubilee clip on it (but not too tight) could this be the issue?

It does sound like it's pulling air through the fuel lines. A return pipe wouldn't normally cause a starting problem, but it's best sorted anyway.

 

Easy stuff first though - Is power getting to the glow plugs? Easy enough to check with a test light or a multimeter (if you're posh).

Edited 29 April, 201511 yr by StevesTruck

hi steve, the glow plugs seem to be working as i heard the relay switching over this morning when it was cold enough for the plugs to operate. But the strange thing is today after clipping up the return pipe i left it for an hour and tried to start it and again it struggled and a cloud of smoke? And it was over the 5deg needed for the plugs to operate. Would the extra air cause the smoking? There are no visible leaks on the pipework that i can see.

heated it and heard the relay click off so heated again and it started no problem and with no smoke?

well the fun continues and I am shifting toward something not working correctly in the pump! I am assuming if the pump timing was out it would run bad all the time? pleas correct if I am wrong. but after searching on this site maybe the pressure regulator is faulty? maybe the regulator is sticking this would make sense as the problem is intermittent? any info would be good.

https://www.youtube.com/watch?v=AaHcx-SewoI

this link will take you to youtube to watch a video of the start up this morning. after this I drove a few miles to take the dogs out and it started fine on the button with no smoke??

Edited 3 May, 201511 yr by robmajor

anyone in somerset that could scan it for codes for me please?

Bit of an update it. Have replaced the glow plug relay and the temp sensor as the gauge dropped like a stone the other day and this made no difference.but today after work I started it and it smoked but I heard a loud ticking noise that stopped after 5 seconds after a small noise? I think this noise came from the fuel pump.

Any ideas?

anyone in somerset that could scan it for codes for me please?

I'm in Bridgwater chap, I have a vcds lead i've only ever used it for mapping purposes. I don't have a laptop though.

Nice one what connectors does the lead have?

It's one of these. http://www.lightinthebox.com/vag-cable-vagcom-12-12-3-diagnostic-cable-for-vw-audi-skoda-seat-english-only_p2452278.html?currency=GBP&litb_from=paid_adwords_shopping&gclid=CjwKEAjwg7yqBRCu5NmlgMm6i08SJADDEudZr4sur1qXhs3KJEo9Co3X3Vez_t1oyxwQD1PqcfcNlhoCBLXw_wcB

 

I brought it so that I could run boost logs ect so that I could have a Faboka re-map.

Thanks chap I did manage to find someone nearby to scan it. No codes except lots of codes for the radio????

I also replaced the pressure regulating valve on the top of the fuel pump but this made no difference.

Does anyone have any experience of fuel pump issues like this?

could someone tell me what the third injector from the left does with the wire on it? are there any easy tests i can do to elliminate the injectors?

Also this morning it was a bit chilly and i noticed the glow plug light was staying on longer and it started quicker but still smoked?

it was colder so the glow plugs were operational and this did help ?

 

after getting it scanned with vcds lite i contacted a member on here who lives 4-5 miles away from me (magicknight75) and he scanned it with the full version and downloaded the timing checker from the ross tech website. And found the pump timing to be hugely out!!! And then he offered to reset it for me! Top man!! And now she starts on the button with no smoke at all :clap: :clap: Thanks alot for your help steve :clap:

Anyone thinking of getting the fuel pump timing changed make sure you have the ability to plug it in to vcds as the smallest of adjustments make a big difference and it was so simple to check with the right equipment.

Thanks to this forum and everyone who helped :clap: