My new swap.. starting problems..

[steevz]

Okay,

so I swapped a 1.9TD into a 92 Passat wagon. It's runs great and I daily drive it to work and home.

ATM:
1. I haven't wired a momentary switch to the glowplugs.. which I'll be doing soon, for now I hotwire from the battery. They were drawing no power so obviously they were all burnt out. I replaced the 2 easy ones with two good used plugs and it 'somewhat' aleveated my problems.
2. I have to plug in the car every night and it's not below 0'C yet, starting after 9-12 hours of work is a problem and it seems to be getting worse.
3. Have lost no oil in the last ~2500kms.


Okay, so now for the hard cold start.

I'll glow for 10-20 seconds with 2 known working plugs, run around the door to crank and engine and I get.. crank, crank, crank, thump, crank, thump, crank, thump.. you get the point. It feels like the engine in on the verge of starting but just can't quite get there.. I thinking maybe out of time. While cranking there is LOTS and I mean, LOTS of black smoke. Starts out white, then turns black after a few seconds and if cranking repeatedly for 30 seconds the car is consumed in black smoke.

When it's running it runs well, and if not allowed to sit for more then 2 hours, starts again with no glow plugs. No smoke while driving.

Could 2 bad glow plugs cause 'this' hard of cold starts? ... well, it's not even really cold yet.. like 10-20'C. Doesn't really matter the temperature, if the engine sits it gets incredibly hard to start.

Is black smoke cause by being too retarded or advanced.. there is no pinging while driving/accelerating and I'm thinking the pump needs to be more advanced.. am I right?

[TylerDurden]

Sounds like two issues: retarded timing and overfueling.

Low compression can also cause hard cold starts.

I'm hoping you post a build thread on your swap, I'm eager to see your efforts before I try one.

[bscutt]

two plugs not working can make cold starts next to impossible if it's cold and compression is a bit low. I would do whatever is necessary to replace the other two plugs.

[steevz]

Sounds like two issues: retarded timing and overfueling.

Low compression can also cause hard cold starts.

I'm hoping you post a build thread on your swap, I'm eager to see your efforts before I try one.

There is no black smoke under full petal acceleration. I'm going to try and advance the pump a bit today and see if it helps. I don't have a compression tester.. but it starts up fine hot, wouldn't it be harder to start with a hot engine as well?

I'll get some glow plugs and pull the pump to replace them, probably easier then messing with them behind it.

[bbob203]

Sounds like two issues: retarded timing and overfueling.

Low compression can also cause hard cold starts.

I'm hoping you post a build thread on your swap, I'm eager to see your efforts before I try one.

plus 1 on the build thread. Im hopefully going to be putting an aaz with an 02a out of a b4 into a b3 wagon. So long as i can import it into the states from canada.

[Fatmobile]

Once the new glow plugs are in; you'll be able to tell if the timing is right.

[steevz]

I used an AAZ with 02a with my B3 wagon too.. I didn't really take any pictures during the build process.. was kind of in a rush to get it done.

I advanced the timing to the point the pump cannot move any further toward the engine and its starting better, still need to get those plugs changed out this weekend. I wonder why I'm getting the pump that far advanced with no knock (marbles on a plate) sound.. is it because of the two stage injectors I wonder?

Could poor injector nozzles cause hard starting? .. and maybe contribute the all the smoke? I know no history on them.. the engine has a good 300k on it too.

[bbob203]

i could possible be off a tooth on timing thats why its able to advance so much without clacking.

[82vdub]

Change the glow plugs so that they are all working properly, and then if you have a cold starting problem, it's something else. Glow plugs are essential.

[Fatmobile]

This is a 1.9,.. and you haven't mentioned the crank sprocket.
You know the key in the timing sprocket is weak right?

[steevz]

This is a 1.9,.. and you haven't mentioned the crank sprocket.
You know the key in the timing sprocket is weak right?

Yes, I am aware of that. I have another D style slotted crank sprocket here for when I get a chance to swap it out.

[air-cooled or diesel]

glow plugs first, then retime to specs w/dial indicator. use a ratcheting wrench for glow plugs and dont lose the small nuts for electrical rail. craftsman has those wrenchs and i think they are warrantied too. they also rotate on their axis. so its easy to get into certain areas.