Very Weird TDI (No Start after Head Swap?) 

Ivan will drive out very early in the cold morning over a mountain to diagnose someone's car. Gives a new meaning to mobile mechanic. I could imagine him being a doctor years ago.

One thing i like about ivan is that he try's his hardest for the customer a rare thing these days

There is only one right way to set the timing correct on a PD TDI and that is adjusting the “Torsion Value”. Using VCDS or another scanner go into “01 Engine” and choose “Group 004” and adjust the “Torsion Value” to +- 2.5 ˚ KW (KW stands for Kurbelwelle ie Crankshaft), when the engine is hot… And that’s it…😊😊😊

This is called tandem pump in my region, as it assists fuel and vacuum for break booster and solenoids. These engines in my experience last very long time, have very low fuel consumption and have reasonable power for the engine size. But there are no engines without problems. Greetings from Estonia! Ivan, good video as usual!

This is not so much for you Ivan as for those who watch/appreciate your content. I’ve been watching Ivan diagnose for quite a while now. It dawned on me recently that I watch several providers that are top notch and almost NEVER like (👍) a video. I’m gonna challenge myself first and maybe some of you to turn a new leaf. Ivan deserves our support! Let’s all agree to develop a new HABIT. Let’s LIKE (👍) every video of IVANs for the entire month of FEBRUARY to show our support and encourage him to keep the faith! THE ENTIRE MONTH OF FEBRUARY!!! Leave a short comment too! Thanks Ivan. 🤠🇺🇸 Let’s “Make our Community(s) Great Again!!!” God, Country, Family, Friends and self. The Code.

Good vid Ivan, have you ever watched DiagnoseDan ? He is really good at finding the problems other garages can't... his CAN BUS knowledge is second-to-none, very logical in his diagnosis of vehicles... He also seems to be the same type of guy as yourself, dedicated to looking after your customer & doing the job right !! 😎👍☘️🍺

I love those dirt roads over the mountain and out of happy valley. Lots of fun and gorgeous views from the top... (4x4 required, of course). Been a while since I have gone that way.

Hi Ivan, Good call regarding the pump. I had a problem with my pump here in the UK. To replace the pump was a silly amount of money so purchased a seal kit and springs from a fuel diesel supplier, just needed engine code/year to ensure the right kit. Once done, perfect and no more problems.

So did you set your timing back to the known good before you unhooked your scope? You had adjusted it a few notches in the other direction, but you never showed whether you put it back to the known good timing adjustment or not.

That is the tandem pump, not the high pressure pump as it just make a little pressure which is fed to the injectors which are independent pumps actuated by the separate cams on the camshaft. Each injectors produces around 2000 bar when hit by the cam, then it is electrically actuated to inject fuel in the cylinder. This PD was actually invented in the US I think and is one of the most reliable injection technology for diesel, but it has it limits related to emissions ...

I just put my tv on your channel and let it play all day in the shop! Always something new and interesting to learn on PHAD! 😊

In Volkswagen and Audi it’s common to lose the pressure of the fuel on the high pressure pump just because there’s a suck fuel injector or rings and most likely the high pressure pump is ok, seal properly the fuel injectors system and you get back the pressure of the high pressure fuel pump.

This is exactly what the auto industry will be doing until they go full electric it’s not always the parts a lot of it is the sensors wiring and computer

Those older bhw engines can be a pain to get the air out of the system. High pressure pump on these engines are also a vacuum pump and arent that high of a fuel pressure. The injectors are what create the high pressure. As to adjusting the cam timing after it starts there is a data pid called torsion value want it as close to 0 as possible.

VW passhit! lol Never been impressed with anything, "VW"!

I just sold my 2003 Jetta TDI and I have to say I was very happy to get 316,000 miles out of it. I purchased it new and did all of the maintenance myself. One of the best cars I have ever owned cost per mile.

well knows what shop to never go to just a bunch of knuckles draggers

Nice drive out to the customer 👍🏼 You’ll be doing 4x4 off-road videos soon 😀

Ya bad "O" rings on a diesel equals lower compression and a misfire. On a gas engine, bad "O" rings can cause vacuum leaks. Good one Ivan! Good thing you had that waveform from the previous VW diesel for comparison.

Nice diag Ivan. I was under the impression that the HP fuel pumps could be damaged if not R&R'd correctly.

I might add the 04 and 05 Passat tdi has only an 18 month sale period in the US and not available everywhere. Only available in the US with the Zf5hp19fl trans.

At first, I thought I had started a video of off - road recovery! I had an older VW diesel and sent the head to an expert head rebuilder in St Louis. After repair, the engine could not maintain oil pressure. Turned out the head had been line-bored for oversize bearing journals but had a cam with std bearing journals. Pulled the head and sent it back. The next time it came back, the valves were not recessed enough, and even with the proper thickness head gasket, the valves contacted the pistons. The third time the head came back, the engine ran ok, but a dope-smoker in Kia pulled out in front of me and I hit him at 45-50 MPH. End of VW diesel.

Whatever it take to get the job done!! No matter if you have to off road, seal a boat hike a mountain or....cool man keep it up

My first thought was injector orings. If they're bad enough it will look as if the high pressure pump is bad. My practice is to replace any oring or seal that has been disturbed. I also use only oem orings since I've been burnt by after market. Especially on International engines. Never messed with vws but I'm sure same principles apply.

For those not too familiar with Diesel engines a good check of the condition of an injector is to do a "leak off" check. This involves checking the amount of Diesel coming out of the return/spill lines when running/cranking. Ideally all injectors should return the same quantity. A defective injector can leak back a lot of fuel and prevent the high pressure from building up. Also combustion gasses can come back up the spill pipes and into the LP side at the filter looking like an air leak. Keep up the good videos and logical approach.

Hi Ivan, There is a pid in live data for that adjustable cam pulley. IIRC it's something like torque or cam torque. It's a number value IE 1,2, 3 etc. after a belt change you set the pulley to give the correct value in live data. Sorry I can't remember what it should be! I do know that it's a VERY FINE adjustment and a killer to get right. Most mechanics over here don't bother as long as it runs right lol I believe it does affect the MPG

For someone not familiar with diesels, this was a mean call to make. She nearly started but the hi pressure pump had gone too far. Nice fix to get her back on the road and on to the next one.

Hey Ivan I love the videos. Had a quick question, live data shows a fuel pump error as pressure drops and everything is brand new. Think it's a wiring issue or the ecu?? I know it's tough to say over the internet.

I love how this diag started. Didn’t just jump to timing, but since no codes after clearing Ivan started with basics. LP Fuel, check. Then spark, and timing compared against known good. Then down the diag rabbit hole we go….BUT WE KNOW WE CHOSE THE RIGHT RABBIT HOLE because of the methodical approach. Always enjoyable learning from you Ivan.

Awesome countryside there, a lot like here in the PNW.

As usual Ivan does only what’s necessary and gets to the end result while being considerate of the customers wallet. I’ve been like that through a 47 year self employed career in home improvements and lived a nice life and never had an unhappy customer. Ivan will only get busier as time rolls on. My grandparents came here from Russia in 1908 so I have that in common with Ivan.

I don’t like the look of those pock marked hoses much !

Had diesel same problem air in fuel high pressure pump seal failure exactly same simtoms

Иван, как я понял ты родился в России? Интересно было бы знать, а в какой области?

Basically this engine don’t have high pressure pump but they do have injector pump so best solution is take a rocker cover up take injector out and check 3 rubber o ring. To install injector you need adjustment. When camshaft pushed injector rocker maximum in you have to louse nuts and 6mm Alan key screws in maximum and return 180 degrees. After all jobs check injector connector they always to slope

VW Tandem pump common failure.

The PowerStroke system you referred to is called a HEUI it’s electronic based on extremely high oil pressures. As fir cam actuated injection systems that’s going back a ways in technology….. thank Detroit 2 cycle design from the 50s. I’m sure there are also more modern designs of that sort. Good work as always Ivan. And I’m personally choosing to have my wife to cut my hair. That’s one area I’m cheaper than you lol. I love reading the comments!

It is a tandem pump (fuel-vacuum) Cranking dry kill them quick.

Beautiful countryside. What's the Bigfoot situation like up there?

ah yes, our beloved PDTDI

I've had 3 of these 1.9tdi powered vw's. In general, vw are crap cars if you can't fix them yourself like most Euro's. But I do have a soft spot for these as they get phenomenal fuel mileage and you can't kill them! There are youtube videos of 400k+ mile examples in a skoda. Running fine, but they take the head off to have a look and it was mint. Just put it back together. In the 2 polo's I owned. They would average 5L/100km (48mpg) mostly around town. And 3.2L/100km (75mpg) on long freeway trips. Of course, every other part of the car is full of electrical ghosts, and trims all fail in different ways. I've even seen them run on chip fat biodisel, no problem!

Im sorry.. but how do you forget to install such an important seal?

Most common failure at TDIs... Wrong Filter hosing, weak clamps on this hoses, harness in the cylinder heat and worn out camshaft (old TDI Not common rail), Injektors and the Best: glowplugs The pump dies Not easy...

That road is smoother than the Pennsylvania Turnpike

Not a hpfp. It's a tandem pump to the injectors. Pressure is developed in the unit injectors. Noone inexperienced in german cars and their repair should be working on these. You dont swap a head on a pumpe duse without closely following elsa pro. Also, the injectors usually require a recoding. Siemens vdo 100% does or it'll run like horse shit

MAKE AMERICA GREAT AGAIN !

First thought headgasket wrong Way around. Oil starvation. Collapsed lifters …

Any answers to your question about the camshaft position sensor signal: "why does it invert?" Maybe there is a sensor input that flips polarity to indicate a mode change for each cylinder, sort of a telltale for the technician....? (How many wires go to the sensor?)

1 bar coming out of a 3bar intank fuel pump ! Anything below 2 bar ya got no chance, and you can’t really get a reading on the vacuum pump besides the vacuum side as it’s a different chamber directly into the head. New tank pump ya in business

Saw on another show that the cam wave form was inverted because the cam was magnetized

Measuring block 003 torsion value for the cam timing , stop it leaking it certainly won’t start block 33 advanced settings bleed the fuel system take it for there

You keep saying high pressure fuel pump pressure but in this and in another VW diesel we were seeing 20 psi? The high pressure should be a couple thousand bar on the common rail. You had to be looking at the low pressure dide of the HP pump.

Ivan, you ever considered coming down south and doing a circuit out here? Bc I have one that I'd be willing to pay and have filmed myself. Wonder if enough of us down here could convince you it'd be worth it. My guess is no and your booked for at least a year out. Anyway

Man I’m so far behind on these videos. We’ve had snow storm after snow storm here the Sierra Nevadas. About 5 ft at my place, no power for weeks and no phone or Internet. Using my cell phone for this but it is slow.

After about half the video I am thinking the high pressure pump is out of time. They are picky about that. Also could be improperly set tensioner.

Is that a BEW engine? ALH is a bit more fun with the injection system, the pumps start sucking air. Can be fixed w/o pulling the pump(bad idea) by changing most of the orings insitu so watch for that.

Those tandem fuel pumps are known to leak fuel into the head. Through the pump shaft seal. And the pumpedüze system is great as long the injectors are seated correctly :)

Вот они знают про насос-форсунк много, у них на канале много видео по дизелям. ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-vRg-PKqoXTA.html

You are a born teacher Ivan. Do you have one or more teachers who taught you when you started that you would like to thank? The teachers I will always remember are Mr. Lukin, Mr. Manfre, Mr. Zipco, Mr. Nichols, and last but not least, my grandfather. They were strict and may not be everyone's cup of tea, but they taught me skills I use almost daily.

Carry on now the bottom crank as it floated harf a tooth 🦷 was out advanced one tooth trying to start it nothing reset timing took belt off put it back one tooth 🦷 it started graph 📈 perfect it did get new fuel filter at rear over axel shaft strange the key way putting the timing out ,even main dealer could not help with the tooth key way problem it was probably from new there was no marks on key way or the crank key way slot problem it was the pulley but there was no oval in key way at was perfect flat just the pulley slot cut to wide strange

WOW- that was a lot of monkeying around with all that timing and pulses etc. A shot of start fluid in the air cleaner would have started the motor and told you you had a fuel problem.

Thanks Ivan another great video for us to watch (Sunday)

It leads one to ponder whether the air you found in the high pressure fuel system was effectively a failed "bubble test" that you would do on a 6.0 Powerstroke.

0:19 Honeywagon

what about the timing ... should it not be as known good

As i said 😊 feel free next time to write me. I'm working just VAG Group. 😊

Their driveway will smell just lovely for the next year or so with that eau de diesel fragrance :)

How was the oil level? The HP fuel pump failure was most likely ALSO allowing diesel to leak internally and mix with the engine oil. The level should be overfilled. However the leaking injector would have contributed to the oil level as well... Strange how the Cam signal randomly inverts. I would imagine a lot of techs getting stuck on that odd behavior and potentially misdiagnosing a no start condition. Great job, Ivan 👍

Иван у меня к тебе вопрос? А за пролитую соляру, не накажут экологи и зелёные ?

Runs as rough as a diesel....lol

Those tandem pumps are always like that. Take ages to purge. Bet that's all that was wrong the begin with.

Sounds like car owner did head replacement diy , and used excuses saying shop did it🙄 who in their the right mind would pay a mechanic at a shop to do something and not bring it back because they screwed it up there obligated to fix whatever they repaired sounds fishy to me

I'm old school. I want to know if there's any smoke. Fuel level?

Thanks for posting the scenic drive through the mountains.

Hello I'm in Europa and whe have many Passat or wolsfagen those engine have fail o ring and seal on. Injector not hi pressure pump or any think those engine are great.

For those torn up Allen bolts.., RBRT bits are the Bees Knees! Bought a set few years ago. No regrets.

There's never a dull moment watching your videos..

Now a days too much tech. Old school first thing a little starting fluid to see if engine starts and go from there.

If this Passat has a split fuel tank, then the pump has broken in one and it will not draw fuel after half a tank.I meant the feed pump in the tank.

yes,,if they took the haead off twice,,did they replace the hpfp twice,,i doubt it..

Here in Germany there are like 50% diesel cars :D love them

Once again logical thinking and following a plan wins. Great job my friend.

Great diag Ivan! I'm confused how the cam signal inverts on a crank no start, that makes no sense!

pinch the pipe at the pump outlet completely (for starting),,

Always first and easiest step diagosing those pd engines is to check oil level.

Lucky you have the jeep as we call them in Ireland because I don't think a Corolla or Yaris would make it down that road.

That was interesting, Thank you. But then again they all are.

Probably sucking in air from the crank case

I ❤️ central Pennsylvania, no better place to live!

How to make a VW sound like a Ford Model-T!

I appreciate the video . Interesting.. thanks

we dont see many of these diesels in the us because they rarely need repair!

Tylko czemu za każdym razem wylewasz paliwo na ziemie ? 🤬😮

Hey Ivan where did you get your pico scope?

When they changed the head they forgot to install the brain that's why it can't run .... LoL

vhy are you having out diesel on the ground😊

I replaced a engine pd 1.9 tdi with two red but want to start

When I think about New York, New York City is the first image in my mind. But the country side of New York is unbelievably beautiful. You're lucky to live there, Ivan!!

Let's see what we got........ Morning sir

Man VAG cars always beep and boop so much!