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Help.. Tdi Suddenly running really rough

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tdi
5K views 32 replies 16 participants last post by  John_Karlsson 
#1 ·
Was driving on the highway at about 50mph when the truck suddenly lost power and started running on 3 cylinders or so it appears. No strange noises or anything. At Idle, its realy rough and appears to be running only on 3 cylinders. ITs also smoking a lot even at Idle.

Any Ideas?
 
#8 ·
Ok... here is what I found so far. Number 1 injector/cylinder is not firing. I cracked the lines while at idle and the first one had no effect on the engine. The other 3 when cracked caused a major drop in the idle. Other then that, it seems to be running smooth just on the 3 cylinders so I dont think its the belt at all.
This is the engine in my dads truck. He uses it every day. But it only has about 3k on it since the rebuild. My guess would be the injector. Should I remove it? what should I look for?

Follow-up Post:

I have never had water of fuel problems before and I dont run any additive by the way
 
#10 ·
You would need to take the injector to diesel specialist to test it. I would certainly recomend running a diesel additive, especially in winter. Optilube XPD is the shizzle of them all, DM runs it as well as I and I constantly get comments about how my engine does not smoke or smell. Helps cold starts and water dispersion too.
 
#15 ·
TDI Guy said:
I will check that as well Jim. Should the injector come out easy? I guess you just take the hold down clamp off and lift up right?
It should come out easily.....


quite often a slide hammer will help a lot. Get a nut that fits the injector thread (300Tdi's are M16 if i remember right, so the 200's should be similar) then i welded that nut, to another nut that fitted my slide hammer, they came out a treat then.

undamaged too.
 
#19 · (Edited)
but...wouldn't that affect all cylinders?

btw what was the cure for that? new crank?


revor said:
You might want to have a look at the harmonic dampener, If it's wobbling then there is a chance the keyway in the lower timing pully is whacked.

We had this problem in Grahams truck and the symptoms seem very similar.
 
#21 ·
hey randy

I can believe it.

glad you found the problem. when you get the new one installed turn the engine over by hand at least twice to make sure everything is moving correctly.

TDI Guy said:
Just took the rocker cover off... Found the problem. Had a broken rocker adjuster screw. Was very lucky. the parts were just sitting in there.

Follow-up Post:

can you believe this? I can't
 
#22 ·
Cool, glad it wasn't anything too sinister. without checking microcat (my PC has crashed funnily at the moment and i can't boot up MC, i think it might be ERC9054 (this is the 4 cylinder NA and TD version... Tdi may be the same)

before you refit it all, just try pushing the top of that valve down, make sure it's free to move, just in case the timimng gear had jumped a tooth and the piston smacked the valve up, causing the breakage.

Hopefully it was just a crap made part, that's all!
 
#23 ·
Good advice from Jim A

I have heard from a couple folks about valves sticking in the valve guide. So check for smooth operation of the valve as well.

Jim P



diesel_jim said:
Cool, glad it wasn't anything too sinister. without checking microcat (my PC has crashed funnily at the moment and i can't boot up MC, i think it might be ERC9054 (this is the 4 cylinder NA and TD version... Tdi may be the same)

before you refit it all, just try pushing the top of that valve down, make sure it's free to move, just in case the timimng gear had jumped a tooth and the piston smacked the valve up, causing the breakage.

Hopefully it was just a crap made part, that's all!
 
#25 ·
The valve cap was sitting right next to the valve. Ordered a new part. should have it by friday. The valve seams to move fine Once I install it, I will crank the engine by hand to check everything though.

Thanks everyone so far. Nothing like some quick pointers to get the ball rolling and help figure out the problem. this site ROCKS...
 
#26 ·
TDI Guy said:
The valve cap was sitting right next to the valve. Ordered a new part. should have it by friday. The valve seams to move fine Once I install it, I will crank the engine by hand to check everything though.

Thanks everyone so far. Nothing like some quick pointers to get the ball rolling and help figure out the problem. this site ROCKS...
Must have been an intake valve, I have seen that happen with an exhaust valve and you would have been describing an entirely different noise
 
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