From owner-fsj-digest-at-digest.net Sun Dec 19 22:29:49 2010 From: fsj-digest fsj-digest Monday, December 20 2010 Volume 01 : Number 3665 Forum for Discussion of Full Sized SJ Series Jeeps Brian Colucci Digest Coordinator Contents: fsj: Diesel disasters, dreams and directions fsj: OT: assorted pictures FSJ Digest Home Page: http://www.digest.net/jeeps/fsj/ Send submissions to fsj-digest-at-digest.net Send administrative requests to fsj-digest-request-at-digest.net To unsubscribe, include the word unsubscribe by itself in the body of the message, unless you are sending the request from a different address than the one that appears on the list. Include the word help in a message to fsj-digest-request to get a list of other majordomo commands. ---------------------------------------------------------------------- Date: Fri, 17 Dec 2010 23:10:02 -0800 (PST) From: john Subject: fsj: Diesel disasters, dreams and directions Diesel disaster recovery: my '03 Jetta wagon is 100% back on the road... what I thought was death by bad biodiesel turned out to be prior owner neglect and worn parts, and an error on my part. My electric pump had a filter unit on it... but it cracked, got tired of it leaking so I took it off. And, the last batch of biodiesiel was pumped out of one of my old 20gal clear barrels... the biodiesel had been filtered by my friend... but the barrel had years of whatever in it... I didn't worry about it because the filters on the cars would get that... and that they did... the '91 benz (2.5L TD) would barely make it up the hill... a filter change cleared the benz for continued service... 267,000 miles and going strong... HOWEVER, the TDI suffered a much worse fate... it didn't suffer power loss like the benz did, but spit up an error code P0252, head pressure... read some stuff on line, ok, filter clogged, makes sense... especially after a bad barrel of biodiesel... filter change and clear the code and it was fine, for about 20 miles, then is started hammering, sounded like a bad injector, pulled over and listened, couldn't find one that was bad, did the crack the fuel line test, nothing... then it stopped making noise, but popped the code again... ok... the injectors had always been suspect, the mileage just wasn't as stellar as reported by other TDI owners... sent 'em off for rebuild/clean, yep, two were bad, one totally broken internally... $409 later... fired right up... and then started hammering again. called the IP shop... yep, they've seen that before with the TDIs they suggested cleaning it with Diesel Purge... ok, yep, that worked... for about three days... hammering/P0252... ok... let's pull the fuel pickup, maybe the screen is clogged, it was pretty nasty... changed the filter, more Diesel purge... code cleared, ran for a day... hammering and code... ok... let's buy the triangle socket... got it, pulled the top cover off... yep, nasty stuff on top, cleaned, reassembled... ran quiet for about 30 miles... pulled it apart, checked inside the pump, looked good, cleaned things, Diesel purge, ok for about 10 miles... repeat process, the last attempt, good for about 1/10th of a mile. I tried to take the fuel metering assembly apart to see if I could fix the slop I found in the armature and shaft... oops... wrench slipped and the low speed part of the vane was bent over... bent it back a bit, but not enough... the TDI would run but it protested vehemently. I knew what the problem was and also that part was $500 at cost, retailed for $1100. A new pump was $1400 at the dealer, anywhere from $650 to a grand to rebuild. Found a few rebuilds on ebay for $500-$800 after core, 2 year guarantee, etc... problem was they were all two weeks out from being ready... Got lucky and found a used 10mm pump on ebay for $250. 100k, good shape, tested out ok, blah, blah... I figured I'd pull the fuel metering parts off the top since my timing belt maybe had 30k on it... got the pump, the sprocket was off... ok, not a big deal I thought, started to pull the top parts and found the wiring was all integrated... not wanting to splice wires and risk screwing up two pumps I decided to just take the new pump to a shop I've known for 25 years and have them swap the pump... they talked me into new belt and water pump, which I didn't protest... I figured buying the tools would be about half the labor, but they'd do it in less time and it would be a long time before I'd have to do it again... So, I drive the Jetta into the shop about 9 miles away... at idle the engine wanted to escape from the vehicle, sounded absolutely horrible... but it made it... and when I pulled in the shop drive everyone looked... guess it may have sounded worse than I thought... P0251 is "Injection Pump Metering Control "a" (Cam/Rotor/Injector)" and P0252 head pressure codes in queue... So, the next day I get a call, this isn't a 10mm pump, it's out of an automatic, it's an 11mm pump and we're not going to install it because it'll break your transmission and cause polar bears to sweat (just kidding, they wouldn't care about the bears, but didn't want to deal with a transmission I guess)... So I call three different Diesel Pump shops, get on the TDI forums, talk to a few respected TDI friends... all say it's an upgrade, will work fine... etc. So I call the shop, explain that it'll be ok, been done before... they consent after I told them I'd take full responsibility if my engine turned into a lump of scrap metal... they said the engine is expensive, I said, yeah, $2700 for one out of a wreck... ok, I knew the risks and they reluctantly continued the installation... another call... uh, we can't index this sprocket, we don't have the tools. Ok, more calls to pump shops... no, we don't have it either, go to Portland, same story... called Portland, the guy was very helpful, said he'd put the sprocket on and test the pump for free, just ship it or bring it on down. So I boxed it up, go it down there. They confirmed it was an 11mm and in great shape but had a bad temp sensor and a leaking seal... plus they dialed the pump back a bit so we wouldn't have to do the hammer mod... they packed it up after I gave them a C note for the labor/parts, shows up, run it to the shop... I put it in the back, let the wrench know and then I notice that the fuel inlet line was missing... I had traded my worn out pump to reduce the costs and they didn't pull that part.. another call, another UPS package... but oops... I had the wrong street address for the shop... yikes, ran over to UPS with the tracking number got it all sorted out... and today they installed everything and I picked it up around lunch time. price breakdown: - - injector rebuild/clean (2 broken) - $409 - - Diesel Purge - around 8 cans x$4 - $50 - - used pump - ebay - $250 - - used pump seal/sensor/dial in - $105 - - new water pump - $69 - - 2 liters of Pentosin antifreeze - $24 - - timing belt Kit - $220 (continental timing belt/idlers ) - - ceramic front brakes (maybe they figured the extra power would require them) - $80 - - rotors turned - $30 - - labor $490 (quote from a very affordable friend/mechanic was $470 belt ONLY) - - SALES TAX - $83.63 (total at the shop - $992.63) so, let's see, excluding Diesel purge - $1506.63 Got an 11mm pump, new injectors and a 100K timing belt... and a brake job... can't complain. - -------------------------------- Diesel dreaming... talked to Curtis, the SD33T/TF727(big block RV)/NP208 is in the '83 J10 frame... he's grinding the frame, prepping for black epoxy. Then he'll spray the cab and bed on a dolly and put the cab on the frame... well, I may go down to Centralia after Christmas and help him set the cab on the frame to paint there. Considering the delays and other issues he has going on I'd be happy to have him shoot it all one color, assemble the major bits and let me drag it to my shop. We'll see... at least then drivetrain is in place... As far as the '83 Cherokee, at this point I'm going to get it home and running, if I have to pull the engine I'll look for a 304 to replace the 360... When I come back up from Centralia with the Jetta wagon after Christmas I'll be bringing my T-5, T-176 and AW4 with the custom adapter to mate to the SJ xfr cases... that will give me some engine options on the WT Cherokee... and less stuff to haul up when I bring Superdawg home. - --------------------------------- So the current fleet contains two Diesels... the '91 300D (267,000 miles 2.5L TD, 30 mpg in town, doing well) and the '03 Jetta Wagon GLS TDI (137,000 miles 1.9L TD, expect over 40mpg in town and mechanically flawless now... but needs about 2k of body work) and then there is the '99 WJ. I think it needs a tuneup, around 10 mpg in town... don't remember when I tuned it last or how many miles... I think it was about four years ago, maybe... and of course there is the mythical superdawg, the '83 j10 stepside that has been torn down into itty bitty parts since June 2001. The Diesel direction is to keep the 300D for my wife, the Jetta for daily use and maybe trips (or the 300D for trips) and then the J10 for utility work and WVO hauling, selling off the '75 J10 hydraulic dump trailer and the '99 WJ... but if the '83 Cherokee is really nice and my wife likes it then the fleet might go 300D, Cherokee and J10 and sell off the TDI, trailer and WJ... we'll see... some popcorn required... (actually should have stated that first... ;) and that's the way it is... john ----- - ------------------------------------------------------------------------ Snohomish, Washington -o|||||o- where Jeeps don't rust, they mold http://AMSOIL.com/redirect.cgi?zo=283461 si vis pacem, para bellum http://johnmeister.com http://wagoneers.com http://fotomeister.us - ------------------------------------------------------------------------ ------------------------------ Date: Sun, 19 Dec 2010 22:28:50 -0800 (PST) From: john Subject: fsj: OT: assorted pictures http://fotomeister.us/2010/12-Dec-19-mtn-camel-cats-7-19/ALL.html a few pictures of mark putting a lock-rite in his '85 GW a few pictures of mac and jack (cats) after becoming certified UNIX. a few pictures of the TDI getting a heart transplant a few pictures of the mountains around here a few pictures of a camel and a donkey and a picture of a jeep... oh, and the christmas decorations. hope you all have a very merry Christmas and remember the reason for the season. in other news I still haven't made it down to look at the '83 WT Cherokee, looks like the 27th. talked to curtis, heading down week between Christmas and NY to lend a hand. Going to bring back the T-5, T-176, and AW4 with custom adapter for SJ xfr case. The TDI is running strong. The 300D is getting 30mpg on pump Diesel. The WJ still has that emissions error code... but running and looking great. john ----- - ------------------------------------------------------------------------ Snohomish, Washington -o|||||o- where Jeeps don't rust, they mold http://AMSOIL.com/redirect.cgi?zo=283461 si vis pacem, para bellum http://johnmeister.com http://wagoneers.com http://fotomeister.us - ------------------------------------------------------------------------ ------------------------------ End of fsj-digest V1 #3665 **************************