Polo TDI no Power

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Polo TDI no Power

Post by MK1-GT »

Hi all...

Need some assistance or if you could point me in the right direction....

Where can I find a manual or can anyone tell me how to set the injectors on a 1.9TDi polo classic... It an ATD motor (74kw)...
Injectors were replaced, and not the car has no power and does not rev up...
Last edited by MK1-GT on Mon May 14, 2012 6:57 am, edited 4 times in total.
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Re: Polo TDI Injector Setting

Post by Neuk »

Morne, sure he can help, I haven't seen much literature on injector setting on PD engines...
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Re: Polo TDI Injector Setting

Post by panic-mechanic »

There is nothing you can user set on an injector.
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Re: Polo TDI Injector Setting

Post by Neuk »

panic-mechanic wrote:There is nothing you can user set on an injector.
All VAGCom related as far as I know...
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Re: Polo TDI Injector Setting

Post by MK1-GT »

Thanx for the replies guys..

Apparently it has something to do with the way the injectors are installed, the angle or positioning.. I found this below but not sure exactly about it..

"you have to use a dial indicator and rotate the camshaft so that the injector arm has pushed the plunger to its lowest point. Once it is a the lowest point you need to loosen the lock nut on the arm and screw in the adjustment screw until it stops. At that point just turn it back 225 degrees or whatever the spec is for your engine and tighten the lock nut. The screw is at the end of the injector arm directly above the injector. They are the ones with a hex slot in the top and a jam nut that locks them down. "
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Re: Polo TDI Injector Setting

Post by G-spot »

Does the car idle? if the car idles fine then it wont be injectors. It sound like the car is in limp mode. Have you scanned the car for errors?
The injectors on the PD motors work off a rocker that is pushed by the cam, AFAIK there is only one way these will fit.
you have to use a dial indicator and rotate the camshaft so that the injector arm has pushed the plunger to its lowest point. Once it is a the lowest point you need to loosen the lock nut on the arm and screw in the adjustment screw until it stops. At that point just turn it back 225 degrees or whatever the spec is for your engine and tighten the lock nut. The screw is at the end of the injector arm directly above the injector. They are the ones with a hex slot in the top and a jam nut that locks them down.
If you simply replaced the injectors then the cam should be in the correct position, so in theory none of the above should be necessary.
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Re: Polo TDI Injector Setting

Post by MK1-GT »

G-Spot wrote:Does the car idle? if the car idles fine then it wont be injectors. It sound like the car is in limp mode. Have you scanned the car for errors?
The injectors on the PD motors work off a rocker that is pushed by the cam, AFAIK there is only one way these will fit.
you have to use a dial indicator and rotate the camshaft so that the injector arm has pushed the plunger to its lowest point. Once it is a the lowest point you need to loosen the lock nut on the arm and screw in the adjustment screw until it stops. At that point just turn it back 225 degrees or whatever the spec is for your engine and tighten the lock nut. The screw is at the end of the injector arm directly above the injector. They are the ones with a hex slot in the top and a jam nut that locks them down.
If you simply replaced the injectors then the cam should be in the correct position, so in theory none of the above should be necessary.

Hey dude..

Yes the car does idle..... We scanned using VCDS/VAG-COM and only fault it picked up was the sensor by the Intercooler which was replaced. Other then that no other faults...
Also thought it was in limp mode of some sort but does look like it.

Other thing I think when he did a basic settings test or something to that affect on group 004 if I remember correct. And it gave something about early and late..
I will find out exactly wat it says..
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Re: Polo TDI Injector Setting

Post by MK1-GT »

I have a question guys...

I was told that there might be a problem with the injectors or rather the nozzle of the injectors... And that they nozzle might need replacing if they are bent or damaged... Is that correct? and can they replace the nozzle or would the while injector need replacing..
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Re: Polo TDI Injector Setting

Post by panic-mechanic »

083 309 5033 dial the number and speak to trevor....
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Re: Polo TDI Injector Setting

Post by MK1-GT »

panic-mechanic wrote:083 309 5033 dial the number and speak to trevor....
Is that Trevor from Dim Sport...
I will call him first thing in the morning.. Thanx....
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Re: Polo TDI Injector Setting

Post by MK2 G60 »

The injectors have to be adjusted.
Trun engine till injector is in fully COMPRESSED STATE the turn the 6mm allan key in till in stops then turn it 180 deg back and lock the nut.
You can not recon or clean the units.I have had more problems from cleaned/recon units than you can inmagine.
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Re: Polo TDI Injector Setting

Post by MK1-GT »

g60 golf wrote:The injectors have to be adjusted.
Trun engine till injector is in fully COMPRESSED STATE the turn the 6mm allan key in till in stops then turn it 180 deg back and lock the nut.
You can not recon or clean the units.I have had more problems from cleaned/recon units than you can inmagine.
Thanks for the info... Manged to sort off come right... Got someone to install them again, I had to get new bolts to hold the injectors down, they one had a wrong bolt...
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Re: Polo TDI Injector Setting

Post by MK1-GT »

Ok after we did that, the car still had like no power... Would only rev up to 2500 RPM's.... Did a scan with VCDS and no faults...

But I think we managed to sort of find out where the problem is but not sure how to fix it. ...
If we take out the vacuum pipe out from the Vacuum ball (not too sure what it called) then the car Rev's up fine. Took it for a drive and also seems to move ok now..
When we push that vacuum pipe back in, car has like no power and only rev's to 2500 RPM and when we drive it has like no power...

What does that Vacuum ball thing do and it that the problem? Or is the problem something else..
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Re: Polo TDI no Power.....

Post by MK1-GT »

ok the Vacuum ball I was referring to Number 5 in the pic below and called vacuum reservoir..

Image
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Re: Polo TDI no Power.....

Post by Neuk »

Kuven - Have a look at the VNT actuator on the turbo, it is run off vacuum and may be getting affected somewhow? The EGR will also run off vacuum as well as the brakes...
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Re: Polo TDI no Power.....

Post by MK1-GT »

Neuk wrote:Kuven - Have a look at the VNT actuator on the turbo, it is run off vacuum and may be getting affected somewhow? The EGR will also run off vacuum as well as the brakes...
Hi Neuk...

Thanx for the info, really appreciate it....Didn't know what VNT actuator is, but google is my friend today.. lol.. :type:

found this link that explains how the VNT actuator works, etc... But that is on ALH enigine, but should work on the same/similar concept..

http://www.myturbodiesel.com/1000q/a4/V ... adjust.htm

Time to do some more reading and checking up...
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Re: Polo TDI no Power.....

Post by Neuk »

Pleasure, the VNT concept should be the same or very similar on the Polo engines...
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Re: Polo TDI no Power.....

Post by Tdi jetta 4 ever »

I am just guessing here but it might be a faulty or stuck egr valve.
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Re: Polo TDI no Power.....

Post by MK2 G60 »

by the sound of things you have the vacume hoses from the vacume block mixed up.
please e-mail me your chassis number and i will mail you a diag of the vacume block hose layout so you can double check it.
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Re: Polo TDI no Power.....

Post by MK1-GT »

g60 golf wrote:by the sound of things you have the vacume hoses from the vacume block mixed up.
please e-mail me your chassis number and i will mail you a diag of the vacume block hose layout so you can double check it.
PM sent... Thanx..
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Re: Polo TDI no Power.....

Post by Tyler »

MK1-GT wrote: It an ATD motor (74kw)...
Well... to be honest, it had no power to begin with :lol: :lol:
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Re: Polo TDI no Power.....

Post by MK1-GT »

g60 golf wrote:by the sound of things you have the vacume hoses from the vacume block mixed up.
please e-mail me your chassis number and i will mail you a diag of the vacume block hose layout so you can double check it.
Hey G60.. All pipes were correct..... Thanks for that info....
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Re: Polo TDI no Power.....

Post by MK1-GT »

So yesterday I took the car to Trevor... He says that it is seems to be a problem on the Turbo.. He plugged in the vacuum reservoir and unplugged Vacuum pipe number 6 on the vacuum unit.. and the Car still Rev'ed up fine..

Number 6 goes to the Actuator Unit on the Turbo....

We left it like that, but when I was driving home the car like went into limp mode and when I did a scan it gave me boost error...

17964 - Charge Pressure Control: Negative Deviation
P1556 - 35-10 - - - Intermittent

I cleared the errors.. But still can back after took the car for test drive..
Then I plugged that vacuum pipe back in and unplugged it from the the Vacuum reservoir and it still seems to be giving boost issues... But drove it for a short distance..

Could it just be the actuator on the Turbo or the whole Turbo itself?
Kuven Aramugam
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Re: Polo TDI no Power - actuator or turbo????????

Post by Neuk »

The actuator could be broken or getting stuck, the turbo vanes could be getting stuck, the turbo could be on its way out, etc, etc. See if you can move the actuator rod easily?
Current Garage:
Daily Drive: 2014 VW Touareg 3.0 V6 TDi R-Line
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Re: Polo TDI no Power.....

Post by jtm »

g60 golf wrote:by the sound of things you have the vacume hoses from the vacume block mixed up.
please e-mail me your chassis number and i will mail you a diag of the vacume block hose layout so you can double check it.
G60, i'm always impressed at your willingness to assist anybody. Greatstuff man!
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