tdi stalling

[clintox]

I have recently purchased a 98 tdi defender 130 at auction at a good price. it needed some love and a attention that I'm keen to spend my hard earned on.

I have recently done the timing belt, brake vacuum pump, and new lift pump, filters, and a new radiator it was running fine before all this and when i went to start it today it started fine and idled fine but when trying to bring the revs up to warm engine and fill cooling system it stalled.

I started it again no dramas revs fine but when i try to bring revs up gradually or quickly it loses all power and runs rough or stalls, if it doesn't stall it will only run rough for a few seconds then back to smooth.

I have not driven it yet and need a few ideas as to where to start looking.

cheers and yes ill post some photos of the new girl

[justinc]

Sounds like an air leak at suction side of lift pump maybe?

JC

[clintox]

its funny you say that JC because i swear that i can hear a sucking noise on that side I thought it might be the brake booster given i have a new brake vacuum pump. it runs beautiful on idle

[langy]

It's possible that you've upset the fuel line whilst installing the vacuum and lift pump. Park nose down overnight and you should see a diesel leak if there is a problem.

[clintox]

lanky lucky where i live there is no shortage of hills i will try this out

[clintox]

no go! I have checked all fuel hoses for leaks and parked on a hill still can't seem to locate fault. I today pulled the wire off the fuel pump and funnily enough when i put it back on i started again then managed to get full revs for a while then then id died to almost stalling tried this process a few times and it seems to do the same thing is there any chance this switch is faulty or maybe I need to inspect this wire?

[jakeslouw]

Check the voltage to the fuel cutoff solenoid?

[langy]

In the same vein as Mr Jake - make up a wire with a spade connector one end and some sort of clamp to the battery at the other. Use it to replace the original wire to the stop solenoid and see if that changes things. If so, then a common fault - corroded and loose connectors ( there are two sets) Carby cleaner and needlenose pliers will fix it.
If not, then the stop solenoid can be removed and the plunger taken out (watch out for a little coil spring -don't loose it). Replace solenoid. Then run engine to see if there is any change. Be warned you then will need to stall engine with clutch and brakes on.

If it still acts up, you may have a dodgy new lift pump ( fit old one as a test) or loose fuel filter or loose water separator ( at the rear).

[jakeslouw]

Heh heh the name is Jakes, surname Louw (Dutch Huguenot surname).

Does the TDi also have a small strainer on the lift pump where the fuel line comes in? If so, check that.

Does the fuel primer plunger prime the system correctly and does the pressure stay maintained? If not, then there is a leak somewhere at the water separator / fuel filter.

[blue_mini]

Is a fuel line crimped? Mine did a similar thing when i bent a line a bit too enthusiatically.

[clintox]

think i got a dodgy lift pump I can't seem to prime filter, its full but I can't get desiel out of bleed screw

[clintox]

Or maybe I do have an air leak whats the best way to test because I can't see any obvious signs

[Blknight.aus]

or you have a clogged line to the fuel water seperator. I've done probably 6 of them this year so far.

[ugu80]

Whilst doing everything else, you might as well check for algae in the fuel. That will clog things up and give you the sort of problem you have. Only fix for that is to remove the fuel tank and clean it out.

[schuy1]

also check the pickup pipe strainer in the tank, that 1 drove me crazy,( well, crazier than I am normally!), for about 2 days once. take cap off tank, disconnect pickup at sedimentor , and give it a blast of air , not high pressure though, it is a fine filter! If that fixes it the tank needs cleaning.

[redrovertdi]

Did you set your tappets at the same time as the other stuff? if so and they are tight that will also produce the same symptoms imo.

[clintox]

Redrovertdi I cleaned water fuel separator and blew out the fuel lines also changed fuel filter again and it seems to have sorted problem out its running nice now.

Adjusting/setting tappets is on my to do list now I have sorted the fuel out.

Thanks guys for all the help
Clint