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When you say cranks do you mean crank revolutions? Or attempts to crank? cold temps and no glow plugs will take a few revolutions. with glow plugs or warm temps it should only take 1 revolution or less.
 

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Discussion Starter #202 (Edited)
In the morning it will crank 4-5 (revolutions) before starting. After it warms up, shutoff and it will start first revolution. Today it was 55 degrees and at lunch time started after 4-5 revolutions. Tonight I verified no leaks, re-tightened all clamps on fuel lines. All fuel lines are new. I have a new filter but have not installed. Going to install tomorrow evening. As far as glow plugs go, I ohm all the glow plugs and they are fine. I tested each connection on the harness (new) all tested 12V except the last cylinder 1.5V which I'm guessing is number 4 cylinder (next to firewall). Must be a bad wire. I can't find any leaks anywhere but seems I smell raw fuel. I was on ebay and really like this fuel filter. Thinking about purchasing one, sure would make it easier changing the filter and eliminating leaks.
On another note, do you have a schematic on how your wired your push button for the glow plugs? I like as many things manual as possible. Much easier to troubleshoot.
 

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I just used a regular 4 pin relay and made my own harness for the glow plugs and have a momentay push button in the cab to ground the relay. About as simple as it can be.
 

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Discussion Starter #204 (Edited)
I'm installing my IP head seal today and I am trying to rotate the engine to determine if the plunger is all the way out. I tried jacking up the rear, placing in 5th gear and turning the tires but engine is not turning. It is safe to rotate the engine by turning the 19mm bolt the connects to the cam shaft pulley. Edit- How to drop the right tire on some boards to keep it from turning.
 

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I'm installing my IP head seal today and I am trying to rotate the engine to determine if the plunger is all the way out. I tried jacking up the rear, placing in 5th gear and turning the tires but engine is not turning. It is safe to rotate the engine by turning the 19mm bolt the connects to the cam shaft pulley. Edit- How to drop the right tire on some boards to keep it from turning.
Just turn the crank bolt in neutral of course. dont turn it from the cam or pump.
 

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Discussion Starter #206 (Edited)
Just turn the crank bolt in neutral of course. dont turn it from the cam or pump.
Replaced injection pump head seal. Hard to see the bottom of pump but was confident clean and seal was in groove..All looked good. Started up no issues.. After driving notived weak boost and black smoke. I checked the timing and off the charts appears advanced How would replacing the seal change the timing?
 

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Discussion Starter #208
Sounds like you missed the pluger detent. any codes?
Plunger dent?

Here are the codes
Friday,29,November,2019,21:48:17:09494
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x64
VCDS Version: 19.6.2.0 HEX-V2 CB: 0.4508.4
Data version: 20190930 DS308.0
www.Ross-Tech.com





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Address 01: Engine Labels: 038-906-012-AGR.CLB
Control Module Part Number: 038 906 012 FF
Component and/or Version: 1,9l R4 EDC G000SG 4104
Software Coding: 00002
Work Shop Code: WSC 00066
VCID: 59EF8EE2000B23AFEE9-4B5C
5 Faults Found:

17068 - Glow Plug Control Module (J179)
P0684 - 35-10 - Implausible Signal - Intermittent
16502 - Engine Coolant Temp. Sensor (G62)
P0118 - 35-00 - Signal too High
16491 - Manifold / Barometric Pressure Sensor (G71) / (F96)
P0107 - 35-10 - Signal too Low - Intermittent
17569 - Manifold Temp Sensor (G72)
P1161 - 35-10 - Open or Short to Plus - Intermittent
17656 - Start of Injection Timing Regulation
P1248 - 35-10 - Control Deviation - Intermittent

Readiness: 1 5 0 0 1

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Address 01: DTCs cleared
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Address 01: Engine Labels: 038-906-012-AGR.CLB
Control Module Part Number: 038 906 012 FF
Component and/or Version: 1,9l R4 EDC G000SG 4104
Software Coding: 00002
Work Shop Code: WSC 00066
VCID: 59EF8EE2000B23AFEE9-4B5C
Fault Codes have been Erased

8 Faults Found:
17068 - Glow Plug Control Module (J179)
P0684 - 35-10 - Implausible Signal - Intermittent
16491 - Manifold / Barometric Pressure Sensor (G71) / (F96)
P0107 - 35-10 - Signal too Low - Intermittent
17569 - Manifold Temp Sensor (G72)
P1161 - 35-10 - Open or Short to Plus - Intermittent
17656 - Start of Injection Timing Regulation
P1248 - 35-10 - Control Deviation - Intermittent
17068 - Glow Plug Control Module (J179)
P0684 - 35-10 - Implausible Signal - Intermittent
16491 - Manifold / Barometric Pressure Sensor (G71) / (F96)
P0107 - 35-10 - Signal too Low - Intermittent
17569 - Manifold Temp Sensor (G72)
P1161 - 35-10 - Open or Short to Plus - Intermittent
17656 - Start of Injection Timing Regulation
P1248 - 35-10 - Control Deviation - Intermittent

Readiness: 1 4 1 1 1
 

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Well your smoke is from a bad coolant temp sensor looks like. That will make it run like crap and not start very well either. you have alot of codes. are you running no MAF?
 

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Discussion Starter #210
Well your smoke is from a bad coolant temp sensor looks like. That will make it run like crap and not start very well either. you have alot of codes. are you running no MAF?
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Well your smoke is from a bad coolant temp sensor looks like. That will make it run like crap and not start very well either. you have alot of codes. are you running no MAF?
No MAF, it was tuned out. I unplugged the MAP while tightening the intercooler pipes. I will check in the morning to see if I unplugged the CTS. I was troubleshooting th glow plugs. If not I will pick one up at auto parts store
 

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Always monitor to coolant temp reading as it can fail open and give you a code and it can halfway fail with a false reading and no code. With no MAF you should have only 2 codes all the time. Glowplug and one for no MAF. The rest of the codes need to be fixed.
 

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Discussion Starter #212
I worked on the glow plugs last week and the only code was the glow plugs. I unplugged the CTS and maybe I need to re-seat the plug. I've never seen the no MAF code. Hopefully today I can't get the codes resolved. Should have rebuilt the injection pump while changing the timing belt.It is very noisy.. The head seal fail apart as I was removing. Its amazing that it could run.
 

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Discussion Starter #213
After re-seating MAP and CTS.

2 Faults Found:
17068 - Glow Plug Control Module (J179)
P0684 - 35-10 - Implausible Signal - Intermittent
17656 - Start of Injection Timing Regulation
P1248 - 35-10 - Control Deviation - Intermittent
 

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Discussion Starter #214
After re-seating MAP and CTS.

2 Faults Found:
17068 - Glow Plug Control Module (J179)
P0684 - 35-10 - Implausible Signal - Intermittent
17656 - Start of Injection Timing Regulation
P1248 - 35-10 - Control Deviation - Intermittent
Output test cycle the N108 doesn't appear to to be stuck. I guess I need to check the mechanical timing?
 

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Discussion Starter #216
yep confirm mechanical and I would log timing while driving and dump the log on malones log viewer.
The mechanical timing was way advanced. Now retard to slightly advanced. Now hope to see how it starts tomorrow.
"log on Malones" Is there a link on how to do this? thanks
 

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Discussion Starter #220 (Edited)
You need to log the correct groups and drive it. no more than 4 things at a time or the resolution sufferes.
The engine seized on me last night. Pull valve cover and they are a mess.... Trying to determine what happened. It appeared the IP was louder than normal. Strange thing other than the 4-5 revolutions when it was cold, it ran really well before the IP head seal change. . Last night I was taking short trips down the road and I return and to the house. Check timing and always advanced but within specs. Oh well, time for engine!
 
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