Thread: smoky 300tdi

check the valve adjustment and the injector pattern.

Timing is retarded.

JC

Thanks heaps to both of you. I will check out all these things and let you know how i go. This should keep me busy after work this week
Much appreciated - Adam

try replacing the seals on the fuel sediment tank.

Originally Posted by justinc

Timing is retarded.

JC

Finally got around to working on the disco today, timing was well out, so thanks heaps, while we're at it, doing the clutch,overhauling the brakes, various gasket and seals and fixing oil leaks in the gear box. Could turn out to be a bit expensive, but oh well, gotta keep it in top shape, haven't fired it up but will let you know if it goes better!

Had a cold starting problem with my '97 Tdi exactly as you described, turned out to be the Injection pump (I.P.) throttle shaft "o" ring seal.
Try this test, only of course if injection timing reset that you have just done has not fixed cold starting problem.
Make sure the fuel tank is at least 75% full, find a slope in your driveway or yard where you can park the vehicle overnight, i.e. where the rear wheels will be at least 200mm higher than the front wheels, park the vehicle with the nose facing downhill, in the morning or whenever, while the engine is cold, try starting as per normal procedure. If, as in the case of my old girl it buttons straight off what you may find, as I did, the leak at the throttle shaft was allowing fuel to siphon back to the tank via the excess fuel return line thereby loosing prime in the I.P, requiring lots of turning over of the engine first start to get fuel up in the injection system.
It seems that with the I.P. so high up on the engine any air entering the fuel side of the I.P will cause fuel to drain back to the tank which is lower, if the vehicle is parked nose up hill or on the level, particularly if the tank fuel level is low.
This test method is a good indicator of this particular problem, and if I am understanding what you describe the engine starts ok every time after, once it has had its first start of the day, that is what mine did.
New "o" ring seal is $1.00, new I.P. top cover joint ring $4.00 from any diesel injection specialist, you need a bit of mech ability and common sense to fit the bits yourself but it's not brain surgery. Good luck.