MK5 Engine Woe's

[Transittim]

So I am having the following issues with my smiley, it's the 2.5TDi with the Bosch conversion.

It's not wanting to do cold starts (winter here at the moment but that normally means only 5-10degree mornings) but once it's warm it seems to start fine, I have read all 10 pages of they cold start issue thread but most of that doesn't seem applicable as it seems to be turning over at quite a quick speed but it takes about 10sec of running the starter for it to kick to life in a splutter and cloud of smoke but after that seems fine, for disclosure sake it has new dual batteries, dual earth leads and I have cleaned the connections.

It seems to have developed a diesel leak at the back of the Bosch pump (hoped I had seen the last of that issue saying goodbye to the Lucas epic) I have attached a pic showing where the drip is occurring at a drop about every 3 seconds.

It also isn't turning off with the key so I am having to stall it to make the engine stop.

Its also recently had an oil and filter change.

Hoping someone might be able to at least provide some clues.

[Chug]

That is the engine mounting block at the back of the pump, so fuel could be running down from anywhere on the pump, BUT you say the stop solenoid isn't working, so I would start by checking if it is leaking from there, then check all the connections to the pump to make sure they are tight, if the pump is leaking it will cause lack of pressure in the pump and make starting harder.

[dumper]

And if it’s not stopping on the key and assumeing you have wired up the stop correct eg not live all the time stop solenoid not working is one of the first signs of pump breaking up inside small bits jam it up we used to get this problem on PSV bus,s sometimes fit a new stop and would be alright but most of the time it would be a new pump anywhere from a few days to months we didn’t get many that leaked diesel

[Transittim]

That is the engine mounting block at the back of the pump, so fuel could be running down from anywhere on the pump, BUT you say the stop solenoid isn't working, so I would start by checking if it is leaking from there, then check all the connections to the pump to make sure they are tight, if the pump is leaking it will cause lack of pressure in the pump and make starting harder.

Yeah, all the joints feel dry underneath so I don't think it is those, ill check the stop solenoid. I am crossing my fingers that it's not the fuel pump, the modified Bosch pumps are very few and far between here in Aus and this one took quite a while to arrive from the UK.

[Transittim]

And if it’s not stopping on the key and assumeing you have wired up the stop correct eg not live all the time stop solenoid not working is one of the first signs of pump breaking up inside small bits jam it up we used to get this problem on PSV bus,s sometimes fit a new stop and would be alright but most of the time it would be a new pump anywhere from a few days to months we didn’t get many that leaked diesel

It has shut off fine for the last two years since I have installed it so I think installation was fine, might just check it with the multimeter to make sure it hasn't shorted out with a positive wire though.

[cherniy_chack]

Hi,Transittim.
Do you live in Australia, where is winter now?
Forgive me for my curiosity.
And now a few questions on the case.
The injection pump Lucas EPIC was replaced by Bosch?
Who made the replacement?
Right after replacement, the engine was turned off from the key?
After what event did you stop turning off the key?
Do you have the opportunity to get to the cutoff valve wire and connect a test lamp to it?
If possible, connect the lamp parallel to the cut-off valve or in its place and monitor the operation of the lamp when the ignition is switched on and when it is turned off.
Poor starting of a cold motor or after a long standstill even in warm weather?
The answers to my questions will help us to understand the reasons for your troubles.

[Transittim]

Hi,Transittim.
Do you live in Australia, where is winter now? Yes.
Forgive me for my curiosity.
And now a few questions on the case.
The injection pump Lucas EPIC was replaced by Bosch? Yes.
Who made the replacement? dieselhead123 from on here.
Right after replacement, the engine was turned off from the key? Yes, turned off fine for a couple of years.
After what event did you stop turning off the key? Didn't turn off with the key a couple of times a month or two ago but then started stopping ok again, then a week ago, started happening again. No specific event that I can recall although I wasn't driving it around the time it started occurring both times.
Do you have the opportunity to get to the cutoff valve wire and connect a test lamp to it? Not yet, but I will when the rain stops.
If possible, connect the lamp parallel to the cut-off valve or in its place and monitor the operation of the lamp when the ignition is switched on and when it is turned off.Will do.
Poor starting of a cold motor or after a long standstill even in warm weather? I think so, it started playing up when it got colder here, but still having the issue on days when it is in the low to mid 20's (winter is mild here)
The answers to my questions will help us to understand the reasons for your troubles.

[cherniy_chack]

I think that the rubber tip of the cutoff valve has collapsed.
It is necessary to unscrew the cut-off valve and inspect the rubber tip.
If there are traces of the destruction of the rubber-valve replace.
But this will not guarantee the normal operation of the injection pump in the future.
Pieces of rubber could get into the fuel pump channels and only a complete disassembly of the injection pump and cleaning of all channels can give an effect.
It will be cheaper to replace the injection pump with another one, serviceable.
Removal of the cut-off valve and inspection of the rubber tip is the first step to correcting.
I wish you success!

[V184]

And if it’s not stopping on the key and assumeing you have wired up the stop correct eg not live all the time stop solenoid not working is one of the first signs of pump breaking up inside small bits jam it up we used to get this problem on PSV bus,s sometimes fit a new stop and would be alright but most of the time it would be a new pump anywhere from a few days to months we didn’t get many that leaked diesel

x 2

[Transittim]

So I finally and found my multimeter and voltage is all as it should be to the shutoff valve so can rule that out. I also chased the diesel leak back closer to its source and marked it in the pic below.

[Transittim]

I think that the rubber tip of the cutoff valve has collapsed.
It is necessary to unscrew the cut-off valve and inspect the rubber tip.

Is this where you mean?

IMG_20180707_154008.jpg

If there are traces of the destruction of the rubber-valve replace.

Any idea of where I may be able to source one online?

It will be cheaper to replace the injection pump with another one, serviceable.

Again, do you know where would be the best place to get one if needs be, not a great chance of getting one here in Aus.


Thanks for the help

[V184]

So I finally and found my multimeter and voltage is all as it should be to the shutoff valve so can rule that out. I also chased the diesel leak back closer to its source and marked it in the pic below.

The bolts snap off in the back, due to the vibration etc

[Chug]

So I finally and found my multimeter and voltage is all as it should be to the shutoff valve so can rule that out. I also chased the diesel leak back closer to its source and marked it in the pic below.

Its probably the pump ditributor head o ring seal, common place to leak, can be changed in situ with care, if you get the pump up on its camplate to keep spring pressure on the distributor head before losening its bolts, see video......


https://www.youtube.com/watch?v=3lm9TM4-b1Y

[cherniy_chack]

Is this where you mean?

Yes.
This valve has a steel core with a rubber tip.
Rubber may have fracture. Rubber crumb can cause sudden engine shutdown and / or power loss.

Any idea of where I may be able to source one online?

A couple of such cases are described in the Russian-speaking segment of the Internet.
I can not give the links.

Again, do you know where would be the best place to get one if needs be, not a great chance of getting one here in Aus.

In my country I can easily buy injection pump, I do not know how it can be done in Australia.

[Transittim]

Thanks for the replies, I just need to get the time to have a closer look now.