Diesel fuel system

[marco72]

My '82 Diesel Westy is exhibiting a strange behavior. It starts just fine and runs pretty well but suddenly (and almost randomly), while going, the engines losses power and eventually shuts off. It then restarts in two or three tries and goes back to life, until the next "automatic" shut-off. The fuel filter has just been replaced and the fuel cut-off solenoid looks fine. Any other idea? Could it be the injection pump ($$$! :-( )? Thank you for your answers!
Marco.

[This message was edited by Capt. Mike on October 12, 2002 at 08:26 AM.]

[Capt. Mike]

First a couple of preliminaries: Although you've changed the filter, has the tank and new filter been checked for water? A slug of contaminated fuel woud also contaminate a new filter right away. There is a fuel filter drain. Try checking after the next shut-down and see if a fuel drain allows it to restart. Also make sure the vent screw is closed back so you're not sucking air.

Air is the other nemisis of diesel FI. Check your fuel dilivery valve for leaks (Bentley 23.8) and finally the injectors themselves. The diesel fuel-injection pump is pretty solid and that your run fine for a while indicates it's the less likely of your problems.

[Capt. Mike]

Transferred to consolidate same topic.

maxyeh Junior Member posted July 02, 2002 09:37 PM

I drive my 82 diesel between sea level and 7000 ft. and back pretty regularly, and above about 3500 ft. I start getting huge billows of black smoke whenever I have to go uphill. Is there a solution?

[Capt. Mike]

A diesel's injection system relies on the same timing belt as the camshaft. It should be replaced on a regular basis as it is subject to stretch and 'out of timing' symptoms. Conventional wisdom seems to indicate every 60K or 90K. Injection pump/valve timing and injection timing are both covered in detial in the Bentley.

In addition to those timing & adjustment settings, diesels require more fuel system maintenance than a gas. Diesels can pick up moisture and a fungus in the fuel system. Thus routine cleaning with an anti-fungicidal such as Diesel Dr. or Penray's (See post under SUPPLIERS) is advised. I use it the last tank before every fuel filter change. At its worst, it will clog the fuel filter but it can start causing rough running or smoke long before that.

Other cleaners (the best being the shop system that runs a concentrated cleaner through the system as a replacement to the fuel tank) can clean fuel injectors and delivery valves. Wear, leakage or improper opening pressue can all give your smoke symptoms. L-M (Also in SUPPLIERS) has an excellent Diesel Purge product that can be used as the filter fill when changing filters. This give a concentrated cleaning effect right after each filter change. It also can be added to the tank. Penray has an equivelent.

Although a certain amount of smoke is normal from a diesel under load and in changing altitudes, excessive smoke can also indicate it's time to check for general wear & tear (compression &/or leak-down testing).

[Capt. Mike]

Transferred to consolidate same topic.

baker6000 Junior Member posted July 25, 2002 10:15 PM

Recently i discovered a crack in the line from the fuel filter to the pump. It actually discovered me as the air it was drawing in led me to stall. I've since replaced this line. The new line was a breeze to put on, but now as my engine runs I have a slow drip of diesel running off of the bottom of the injection pump!! It doesn't seem to be coming out of any of the deliverys..... no history of leaks before. Engine runs but with this drip. What could be causing this drip????

SOrry ,,, I forgot to mention My van is a 82 diesel westy, Anyone out there have a line on this sort of problem?
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Posts: 3 | From: Bay City, Mi 48706 | Registered: July 25, 2002

A. Cooper Member posted July 29, 2002 10:20 AM

Leaking diesel pump

I too replaced this same fuel line on my 1983 diesel about a year ago, as the original line material seems to become very hard and brittle after nearly 20 years!

First, be sure that the leak is indeed originating from the underside of the injection pump. As Capt. Mike often points out, such fluid leaks can be difficult to track down as they sneakily drip from their source to another part to another part before finally dripping free. By the time you spot them, you're off their trail. It's quite possible y our leak is in fact coming from your new line connection, then sneaking down to the underside of the pump before finally dripping.

Such a fuel line-connection leak could be caused by a less-than-neat end where you cut it to length, or an overtightened clamp. Be sure to use the smooth, OE-type of clamp; the tiny slots found on the typical hardware store hose clamp, which engage on a tightening screw, will sometimes chew up your rubber hose and cause a leak.

Also ensure that the hose you bought is indeed suitable for DIESEL FUEL. The kid at my local auto parts store claimed mine was, but within three days it was 'sweating' fuel. When I went to remove it, it fell apart in my hands. After buying the correct, diesel-compatible line elsewhere, I went back to the original store and 'instructed' the staff on the danger of blowing a line and squirting fuel around a hot engine compartment.

Finally, it is in fact possible that your pump is leaking. Although very durable, those Bosch diesel pumps can develop a le ak at the bushing around the main sprocket-driven shaft. They also do not take well to slugs of water or air. If you've had an air leak in your supply line for a while, it's possible the pump's internal impellor vanes, bearings, or seals have been damaged by sucking all that air. For sheer complexity, these pumps are probably tied with automatic transmissions, so if you're sure it's bad, buy a new one or send yours in for a rebuild.

Check the easy and obvious (or not-so-obvious) things first, then work your way toward the difficult and expensive parts.

Good luck!

baker6000 Junior Member posted July 30, 2002 02:27 PM

Let's say in some way dirt (any kind of crud for that matter) got into my pump,,, is this the kind of results one might consider in this event, the drip is for sure coming from one of the two holes on the underside of the pump... is this a typical place for fuel to come out of if say one of the needles were to be clogged with dirt?

A. Cooper Member posted August 05, 2002 05:50 PM

No, these injection pumps do NOT appreciate ingesting dirt or any foreign matter; they have very delicate innards which can be damaged by such crud, so one must be very careful when working on or around them. I've never had this particular symptom so you should really consult a professional. If you're sure that's the problem, you'll need to rebuild or replace it.

Make sure you're sitting down before calling your local VW dealer for a price on a replacement. Once you've recovered, do a web search for a Bosch-certified rebuilder or reseller.

[Capt. Mike]

Transferred from older posts to consolidate diesel topics.

herbpowell Member posted May 20, 2001 06:59 PM

I have an 82 diesel westy. My glow plug light goes out when the westy is ready to start but, after it is running the light comes back on but dimly. It stays on and it's brightness does not change. Does this mean my glow plugs are on? Has anyone else had this happen?
Thanks, herb

ke Guest posted May 21, 2001 01:12 AM

If you look at the Bentley 97.37, you'll see the glow plugs only come on when the relay is closed (circuit #20), thus it's unlikely they are on while the engine is running. That would be easy to check -- test light after they indicator light has come back on.

The activation circuit, #29, feeds the solid-state module that contols the glow plug power AND the gauge panel that contains the pre-glow light. The pre-glow light circuit runs back to that same module.

My guess is the module (circuits 17-19 or the ignition switch itself (labeled pre-glow/strtr sw) is the culprit. I'd lean toward the module. I believe Volkspeak for the module is the "glowing-time relay"; it's located in the engine compartment. I'd suspect the multiple circuits through the module are bleeding back into the glow-plug indicator circuit.

Capt. Mike Tech Writer posted July 27, 2001 01:46 AM

Need HELP with my 98 TDI Please!

MichaelF Junior Member # 1733 posted 07-25-2001 07:15 PM

Can anyone PLEASE tell me how to prime the injector pump in a 98 TDI? Please?

Capt. Mike Tech Writer posted July 27, 2001 01:58 AM

Bentley manual, Vol I; Section E23-5, step 11.

[This message was edited by Capt. Mike on March 02, 2003 at 07:17 AM.]

[Andy-from-ohio]

My current situation is that I am looking for a used fuel injector for my 82 diesel westy. I understand that VW made these engines for a number of years and used the engines in a number of models. Does anyone know what years and models are safe for replacement parts?

For example, I found a Diesel injection pump on Ebay from a 1979 VW Rabbit. Would this fall into the "safe" category? Thanks! I have had this westy (my first) for two months now and have loved this website. HOpe to get to know some of you other users one way or another.

[Mike Robinson]

I would check the part number on your pump with that for sale on 'e' bay.

I could not find the correct part number on busdepot.com - fairly reliable for part numbers. Give your local VW dealership a call my local dealership is really helpful with parts.

Good luck with the diesel, welcome to the cult in a cult. IE Westfalia and diesel.


Mike

[Capt. Mike]

Transferred to consolidate same topics.

uromicitisis Junior Member posted January 10, 2003 05:17 PM

I have checked my Bentley manuel and the archives and I didn't see my problem covered in either. My 1982 Westy Diesel is leaking diesel from what appears to be somewhere around the base of the injector pump. It looks like the diesel is leaking from around a small, about 1.5"L X.75"W, plate on the side of the pump. The Westy is running and starting great. It just leaks diesel all the time, even when sitting. Please tell me I don't need a new pump and that this can be fixed.

Mike Robinson Member posted January 11, 2003 04:43 PM

Leaky pump

Sorry I have no great answer - just as a fellow '82 diesel owner I thought I would pass on my thoughts.

Leaky fuel anything is not good.

One of the first jobs I had done on my westy was relacing all the fuel line and clips, with a 21 year old vehicle stuff wears/degenerates.

If I had this I would get it to a dealership or someone who specialises in things VW and Diesel and get them to check.

As far as I am aware the injector pump is not something that most dealerships repair - it usually goes to a Bosch repair place.

Good luck

Mike

[Capt. Mike]

Of the 2 Bosche diesel pumps I have on hand (neither as used on the VW) only one has a plate. It is an assembly/maintenance access and would have a gasket underneath. Go to your VW dealer (Guideline #8) and see if there is a replacment gasket available; if not or NLA go to Bosch direct in Chicago.