Ahhh, a new to me '04 Passat- project that is - VW TDI forum and Audi TDI forum

Elbonk · #1 08-07-2012, 08:20 PM

Hi, I've got an 04 Passat TDI that was an auction rescue. It runs rough. Powersteering squeeks and there is another noise up front- it sounds like an accessory- but I'm not so sure. The fleet mechanic said they replaced the alternator, PS pump and idler. He stated it was running fine until the driver was coming back from a trip and was leaving the airport and said it had no power. I've checked the front end accessories and everything seems OK. There is a fair amount of bobble on the oil cap- maybe that is blow-by? I checked compression and got 480 to 500 psi. There is a fair amount of oil on the hoses before the turbo (CCV condensation?) and then all the way back on the charge air hoses and some oozing by the MAF and EGR valve.. I have it apart and will clean all the parts up before I run it any more.
I checked the cam and there is some definite wear but no trashed lifters/cups on the valves.. The rollers on the rockers have some lines but no major galling or grooving.
I'm curious- If the cam goes flat can the exhaust valves close too soon and the combustion gases trapped in the cylinder caust excessive blow by? Thus, excessive oil in the EGR and CCV?
As for the oil cap test is that an accurate indicator of blow by? My old OM617 mercedes diesel will idle with the oil cap just sitting in the hole barely moving..
I've found the issues with the cam and the oil pump, I don't know if all the injectors are firing either. The turbo spins free, moves a little side to side but doesn't contact the housing. I vacuum checked the actuator and it seems to move freely. I don't know if might have a vacuum leak elsewhere or if my vacuum source is still good..

I also was curious if the Meyle glow plugs are a good replacement- I kind of dropped one during the compression test-OOOPS. IF so, does a 27mm tip sound right?

Thanks in advance, this sight is excellent..

chittychittybangbang · #2 08-08-2012, 01:15 AM

squeaking is normally serp idler pulley or alt pulley so that kind of rules those out, could be serp tensioner

Oil cap should be tight, what do you mean bobble? With the cap loose? If not familiar with TDI, the vac pump exhausts into the head so there'll be some air coming out there and your compression is fine. I'd say it sounds OK just based on what you said.

See CCV oil leak repair: http://www.myturbodiesel.com/1000q/b...engine-tdi.htm just put some gasket maker there

closed valves = no since otherwise every combustion there would be excessive blowby. Worn cams = valves not opening, rough idle, low power, other bad stuff.

Meyle should be OK, I also use Beru. Don't know how long but plenty of online vendors.

Also check out the b5 buying guide for other catch up main, common probs.

Good luck! Sounds like you'll need it with this rescue

Elbonk · #3 08-08-2012, 08:57 PM

Yup, I've been hammering on the FAQ and the B5 guide.

I found one post where someone made a block off plate for the EGR-- Are there any bad consequences, like a code getting thrown or can the computer even tell?

CCV- is it bad to vent it like the old school rigs or will it just get oil all over?

chittychittybangbang · #4 08-09-2012, 12:32 AM

car knows, MAF feedback loop, will still run fine w/CEL, won't pass emissions w/o chip reflash to account for all this

It'll get oil all over and leave an oil slick in the engine and onto the road. Some people use catch cans and empty it out, I just route it back like it's designed, no leaks w/gasket maker. Plus, diesels have some blowby and exhaust for vac pump has to go somewhere. I don't want to restrict it at all, can lead to burning oil due to pressure in crankcase.

Elbonk · #5 08-09-2012, 01:16 AM

Gotcha..
As for the oil cap I was referring to loosening it. I have done this on different diesels I have and there is differences on similar motors on how much the loosened oil cap moves. An old tired mercedes OM617 vs. an old but not tired one, for example. I know the piston reciprocation affects the air flow-
The older diesels with a direct CCV was an obvious place to look for blow and measure if you have the tools. I don't think this is my issue.

Elbonk · #6 08-18-2012, 08:51 PM

Bullseye Chitty!! I've got a bad OAD or ADP Alternator pulley.. I found some interesting links to videos here and on the TDI forum.. One of them I had seen before when I was seeing if there was some way to settle down my cummins serpentine belt..

http://www.youtube.com/watch?v=yxV1awVFskA

Is the pulley a clutch type or a decoupler type, the ladder moves both ways but is limited one direction and spins with little resistance the other way vs. one way or not at all.
As for the loss of power I found a messed up O-ring right by the intake manifold-hoping to get that next week. I saw one thread that a guy said the OEM gaskets were reusable, is this true?
The other question I had was about sourcing the alt. pulley (number 022903119C). I found an "INA" brand (Made in Germany) for under $60 shipped. Is this a good brand? Just for kicks I have tried to get my local parts houses and even the VW shop to source parts and they have a real hard time finding anything..

Elbonk · #7 08-18-2012, 11:19 PM

http://www.youtube.com/watch?v=4EXYP...eature=related

This link gives some more clarification on the different types of pulleys. While looking for info on what is best the manufacturers/suppliers frown on doing anything other than using what the system was designed for.
On my older cummins engine the belt jumps around so bad that is will wear through the radiator hose if it isn't guarded and it would seem to make sense to upgrade to a clutch or decoupler pulley..

chittychittybangbang · #8 08-19-2012, 01:58 PM

great find on the vid, already added to FAQ! I don't know why editors always add porn music when silence is just fine.

INA is OEM supplier, good brand

Elbonk · #9 08-19-2012, 07:57 PM

Ok, so I found the 022903119C and also the 022903119D, A and B- the parts suppliers show them as replacement parts. I don't know if they are OWC's (One Way Clutch) or OAD's (Overrunning Alternator Decouplers). I have a few emails out and will let you know what I find. I would think a decoupler would be better judging by what the videos show..

69mach1377 · #10 08-20-2012, 01:39 PM

Quote:

Originally Posted by Elbonk

Ok, so I found the 022903119C and also the 022903119D, A and B- the parts suppliers show them as replacement parts. I don't know if they are OWC's (One Way Clutch) or OAD's (Overrunning Alternator Decouplers). I have a few emails out and will let you know what I find. I would think a decoupler would be better judging by what the videos show..

The latest one is silver and not black, IIRC. $60 seems a bit low for the right one, which should be a 'D' suffix.