Project Domes shonky autos - Car that lived by the sea in Scotland in rust shocker*

[Split_Pin]

Thats surely too new to be a fixer-upper. Oh wait, its 12 years old, where the heck did the time go 😮

[dome]

OK so I got an email from someone I know who had been left with this car when the owner had to leave the country to go back to Brazil. The car had been diagnosed with a few issues but it's safe to say something was getting lost in translation/lack of technical knowledge.

"From the email chat "It has recently had work done (couplets or something replaced?, but seemingly needs a new crankshaft. I think. "

Of course when I googled this engine(1.4tdi 3 cylinder PD) it turned out that the oil pump driven off the crank can fail so this did seem entirely possible. 

Some further probing got this

 " thanks, the diagnosis is still to be run in the car, I think what I've changed the last time was the couplets around the crankshaft, looks like mini pistons. No paperwork on that in the car I'm afraid as I didn't bother to get from the garage last time, again he can have a look and run the car if he wants to."

Well, that was clear then.

So, I went for a look at it. 

First things first, I popped the bonnet and discovered this.

All 3 glow plugs were unplugged. Now, as the car has sat since January it's safe to say it wouldn't have been running very well in the cold like that. 

I plugged them in and plugged in my code reader. It gave a load of faults, mostly related to the glow plugs but also a P0234 for boost pressure.

I cleared all of these and fired it up.

 

Hmm. That chuffing and oil leak is coming from the tandem pump, a fuel pump on the side of the head driven off the camshaft. 

It could be as simple as needing a new gasket or it could be more serious.

A brief drive didn't bring the EML on. It felt slow but that was more down to it having 80 odd BHP and me driving to view it in the Kangoo with 100 BHP more...

Other than that it was the usual neglected car-flat tire, handbrake stuck on, general clunkiness from underneath somewhere. 

An offer was made and accepted and that made me the proud* owner of another quality VAG product. Cough. 

So, back home and I gave it a quick wash and soak in TFR to see what we had.

Not too bad. Pretty straight but it's a long time since it's seen polish. That can wait though obviously. 

I popped the wheels off to see what i could find. Recent discs and pads on the front and possible struts/springs too

The rear brakes were pretty manky inside and the shoes have been replaced at some point as they are Mintex, all I've done for now is clean them up.

 

It's currently tucked up in my lockup awaiting parts arriving.

On the basis of my investigations I've ordered the gasket that goes between the pump and the head, an inner and outer track rod and a drop link on the front. 

Obviously sorting out the leak on the head is the priority, I'll see what happens when I replace it. I was a bit concerned with the amount of crankcase pressure, not sure if that's normal for a PD engine?

Oh and the Rangey decided yesterday that it wanted to have the heater fan all the time, whether the ignition was on or not. I've pulled the fuse for now. First culprit is the cheap ebay resistor I ordered so I've ordered a less cheap one to see if that fixes it.

 

[Split_Pin]

I stand with you in solidarity in the face of 'new project anxiety'. 

Sounds like you at least know what you are doing!

[Cord Fourteener]

Solidarity with you on the Ibiza front, Wifey has one as her commuter. 1.2 pez.

I think it's a brilliant thing, I like it more than she does...

[dome]

1 hour ago, Split_Pin said:

I stand with you in solidarity in the face of 'new project anxiety'. 

Sounds like you at least know what you are doing!

If I knew what I was doing I wouldn't have bought another broken PD engined car!

First the A2, then the Octavia, now this.

 

[Cord Fourteener]

 

1 hour ago, dome said:

If I knew what I was doing I wouldn't have bought another broken PD engined car!

First the A2, then the Octavia, now this.

 

It sounds like you need the forum bike Passat after me...

[big_al_granvia]

i hope you didnt pay much more than scrap value for that seat, looks alright for a mule to go the messages in

[dome]

New hedgehog(blower motor resistor) arrived for the Rangey today, it was indeed the one I bought 2 weeks ago which had gone faulty. At least I had practice in changing it. The eBay seller refunded it straight away without question which was good. I suspect because they get failures often...

The Kangoo also has a new track rod. It got an advisory for the inner but I bought the outer too. A good job as it turned out, the old outer had to be chopped off.  

Gearbox oil to change next

[Cord Fourteener]

2 hours ago, leanycan said:

I'm next in line for the Passat.

Don't worry you'll get your next two weeks with it!

[Dave_Q]

Steady when tightening the bolts that hold on the tandem pump, I stripped the threads on a Fabia I had once and had to helicoil.

Alloy head + not that much thread engagement.

[dome]

3 hours ago, leanycan said:

I'm next in line for the Passat.

I'll not stand in your way!

[dome]

Just now, Dave_Q said:

Steady when tightening the bolts that hold on the tandem pump, I stripped the threads on a Fabia I had once and had to helicoil.

Alloy head + not that much thread engagement.

I did wonder if that's why it's leaking so badly, especially if it's had work done recently😬

[Dave_Q]

Mine was a 1.9 but I'm sure this will be the same with one less cylinder. 

I was able to successfully helicoil it in place, obviously the head is quite easy to drill and tap. Think I had to take the battery box out to get the drill in.

So just cost me £30 or so for the helicoil kit.

Mine was leaking diesel down the block, I think that was coming from the actual pump though (it's been a while so can't remember 100%) and the stripped thread was just ham fisted reassembly, if yours is just leaking oil the pump is probably OK.

[Dave_Q]

Also just twigged that the pump could be the source of your boost fault code as the turbo actuator will be vacuum driven, if the pump isn't providing enough vacuum that could be all it is.

[Crackers]

Those pre-facelift Ibizas are a really smart looking car IMO. I got very close to buying a 3dr one a couple of years ago, the idea of the 140bhp 2.0tdi sounded quite attractive in a little car! 

[dome]

3 hours ago, Dave_Q said:

Also just twigged that the pump could be the source of your boost fault code as the turbo actuator will be vacuum driven, if the pump isn't providing enough vacuum that could be all it is.

I've only ordered the gasket that goes between the pump and the head for now. It arrived today actually along with the drive link but the Kangoo is still on axle stands so it'll have to wait. 

[dome]

Ibiza update.

The new tandem pump gasket arrived so I changed that last night-not too bad a job but a bit tight. 4 bolts hold it on to the head. 

 

 

The old gasket was very oily but hadn't obviously failed. I cleaned up the mating surfaces 

 

Back together and fired it up and initially it seemed OK. After a quick test drive (on my private test track) when i got back it was still leaking. Bugger. 

I did a bit of prodding and eventually found a possible cuplrit.

Going back to this picture, see the rocker cover bolt circled? The one right above the tandem pump where the leak was?

 

 

Yep, it was loose. Like, properly loose. Balls. 

I went back round and torqued all of these up but it's still leaking. I guess a new rocker cover gasket is in order then. 

One of the bolts looks a right arse to get to round the back. Hopefully I can get to it without removing the inlet manifold but it'll be tight. 

I also got the flashing glow plug light on my test drive after unleashing all 80 odd horsepower. I disconnected the battery to charge it overnight though before I read the code. No doubt it'll be back.

[bigfella2]

Was it a bitch to start after the gasket change? I need to change mine when I can be motivated.

[dome]

26 minutes ago, bigfella2 said:

Was it a bitch to start after the gasket change? I need to change mine when I can be motivated.

Yeah it did take a bit of cranking. I wasn't expecting that as I'd removed the pump complete but it obviously upset something. 

[dome]

I had to buy a long reach T30 as one of the rocker cover bolts was toit. Got it off and look what I found.

I'm going to suggest that I may have found the source of the oil leak.

 

[bigfella2]

While you have the rocker cover off have a good look at the condition of cam and lifters.

[dome]

6 minutes ago, bigfella2 said:

While you have the rocker cover off have a good look at the condition of cam and lifters.

I can see lobes, that's good enough for me!

 

[Fraz]

7

2 hours ago, bigfella2 said:

While you have the rocker cover off have a good look at the condition of cam and lifters.

Cam + lifters present = check

[dome]

There's a lack of pictures on this latest update; I'll blame that on a mild hangover this morning and an urge to get things done. 

First up I jacked it up to get the track rod and drop link changed. Needless to say these were a pain until the angle grinder came out to play.  The drop link was easy enough once I'd ground off the old one.

I'd chopped down a 32mm spanner to change the inner track rod on the Kangoo, handily this also fitted this. It was easier to get the Kangoos one changed than this one though, it was tight. The inner track rod was well fucked-it had been an advisory on the last MOT. I'd bought an inner and an outer to make things easier. This was handy as the outer started to rotate as I undone it. The grinder came out again to cure this. 

Back together and I stuck the spare on so I could get a slow puncture repaired.  I also stuck a new air filter in it.

I then cracked on with the rocker cover gasket. I stuck a bit of sealant on where it curved round the cam. I got it all back together and torqued down then nipped in to town to get the puncture fixed to give the sealant a chance to dry.

Back home (via KFC for very probably the first time in the Jags life) for a quick test drive.

All seemed well with no EML. The Aircon is nice and cold which is a bonus. Back home and there's no signs of smoke under the bonnet, hopefully thats the oil leak cured. I've booked an MOT for Wednesday. Fingers crossed it'll be ok!

[dome]

2 things happened today which made me happy. 

First, the Ibiza passed an MOT 😁

Second, for the first time ever, I didn't have to pay to tax a car!

Free tax ftw!

I'm so happy that VW did such a good job on getting the smokey old PD engine through such a strict emmisions test back in 2009. They must've worked really hard to do this. Congratulations on some good, old fashioned, honest* engineering...

Next up, oil change and get the tracking straighter after fitting the track rod. Then I'll get some miles on it and get it cleaned up and ready to sell. 

[dome]

I got this back from the MOT station yesterday and did a quick oil change. While doing this I took the tyre with the puncture back to National to let them have another go at repairing it, which they seem to have made a better job of this time.

While there I got them to do the tracking on the van after I'd fitted a track rod to it, it's driving straight again which is always good.

I also had to do the Ibizas tracking after changing a track rod on it too. This was achieved by adjusting it, driving it, adjusting it again til it felt right. I've got it pretty good now, as my 20 mile motorway commute today proved. No issues to report, will continue to use it to let it prove itself before advertising it.

[dome]

Got some stuff done today. 

Boring stuff first, Ibiza got a clean and a polish aswell as a hoover. It came up pretty well. I was going to go and take some pics of it but then it started snowing. Again!

[dome]

Range Rover next. The LPG system on it had been partly removed at some point and the recommissioned by the guy I bought it from. While it worked ok I wasn't happy about the hose used in the engine bay. I found a local specialist and too it to him to get it assessed. He pointed out a couple of things needing done and sold me the require parts to do it. 

The system runs copper pipe to the engine bay and then hose to the vaporizer. As you can see though, the unions and hose were questionable and not LPG suitable.

New correct LPG hose cut to size with unions fitted.

On at the pipe coming from the tank.

And at the vaporizer.

Routed correctly under the scuttle, out of the way of the  wiper mechanism.

 

Much better. That existing setup was extremely shonky. I'm glad I changed it before it failed.

At the tank end I removed the connector to fit some ducting over it leading to where it exits the car.

The idea is is there's a leak from the tank valve it'll carry the gas out of the car. While in there I replaced a single flare on the copper pipe with a safer double-handily this was familiar territory after doing the fuel and brake lines on the Jag. It's on the left here, heading round the tank to exit at the front of the spare wheel well.

On firing it up I found one of the oil leaks...

Never seen that before! I had oil and filter in stock so dropped that and replaced the filter and oring. Hopefully that'll help.

Once warm it switched onto LPG ok and a quick test drive confirmed all was working. Whew!

[dome]

Oh, and Duncan popped by with the MR2, which he's gone and had painted without telling me. Its looking braw!

[Cooper1]

This is all very good..

You had me at the RR goodness and they're indeed great motors to smoke around in  

 

The M62 cam cover leak never seems to stop plaguing these engines, the gasket quality tends to play a big part OEM ones only