Question about 2005 Volkswagen Microbus

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Bought a VW Caddy pick-up a few months ago. It has the original 1.6 diesel engine and was running reliably until I recently changed the timing belt and head gasket. Now the engine starts but is extremely noisy and there is very little power when pushing on the accelerator. Very quickly the engine overheated and sprayed boiling water and oil. The engine sounds as though there is something loose, may be not attached properly, but I have checked it all and bolts, etc. are tight. Also the timing is set correctly according to the book. There is black smoke. Took the thermostat off to check that but unfortunately broke it, however the thermostat did work when put in boiling water so don't think that was the problem. A previous question and answer suggested that the timing needs to be slightly out to produce some of these symptoms. If that is the case, how and which way should the timing be altered. Any ideas please? T

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  • joyjordanass Apr 07, 2011

    Thank you for prompt reply. 'Mechanic' has gone to bed now with headache from trying to find solution (1.00 a.m. here). As soon as it is daylight, we will return to pick-up, armed with your reply and hopefully we can also obtain the suggested tools. Will keep you posted after that.

  • joyjordanass Apr 09, 2011

    Followed instructions re timing and engine is running better. It is still quite loud and there is not enough power. Tried to make fuel adjustment, by sound and smoke colour. Think it is running best when slightly rich fuel mixture but the truck still doesn't have enough power (although drivable when test driven). Any further suggestions please? Definitely not dirty air as it has new air filter and cleaned air box. If the problem was with the injectors or valves, would this effect the power lack, also bearing in mind that the engine appears to tick over well enough and starts easily at first turn.

    Thank you.

  • joyjordanass Apr 15, 2011

    Engine improved and work continued until mechanic came along to see what I couldn't. The timing was still the main problem apparently and he adjusted several times until it was running properly. There is also too much oil floating around which I am trying to clear and now the engine appears to be OK. Not great but I can get around. Will continue to look at suggestions offered by Helpmech. Need to get a new set of hoses if you/anyone can give a clue as to where I can find full set. Ebay has some but not all. Conclusion is that Helpmech was quite right in suggesting timing was problem. Although I thought I had got it right it did need further adjusting. Have learnt a lot!

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  • Volkswagen Master
  • 5,370 Answers

The timing marks are not set properly.Its out of timing.you require the tools to replace the belt.A flat bar vw tool no.2065a to secur the cam shaft in position and a pin vw tool no.2064 to fix the pump position.-------- After removing the belt covers mark the old belt and all three sprockets. Remove the old belt, mark the new belt to match the old belt. Install the new belt matching the marks. You can pull on the tensioner by hand while tightening the nut.Adjust the belt so it turns 45 to 60 degrees when twisted between the cam and IP sprocket.------- The camshaft setting bar, just turn it 2 turns on the crank.You shouldnt twist to check tension of the belt as it breaks the strands inside it thus causing premature failure.Turn crankshaft clockwise to TDC on No.1 cylinder. Ensure crankshaft sprocket timing marks aligned .If locating holes not aligned: Turn crankshaft one turn.Fit timing belt in clockwise direction, starting at crankshaft sprocket. Ensure belt is tight between sprockets. Temporarily fit crankshaft pulley. Ensure timing marks aligned.If the belt is missing its alinement's, then it will give such starting problems. ----------- Black Smoke
This is due to a air to fuel ratio imbalance, either the fuel system is delivering too much fuel into the engine or there is not enough clean air (oxygen ) a few things to look for :

  • Faulty injectors .
  • Faulty injector pump.
  • Dirty air cleaner.
  • Problems within cylinder head, valves clogged up due to faulty EGR (exhaust gas recycling unit).---------- This should help.Keep updated.Thanks.Helpmech.

Posted on Apr 07, 2011

  • raj somaiya Apr 07, 2011

    Yes keep updated with the details.Thanks for the update.Helpmech.

  • raj somaiya Apr 09, 2011

    Yes, if the fuel injectors are leaking, then fuel pressure gets low and can cause this types of problem.But also check the fuel pressure.If the pressure is checked, low then its issue with fuel pump.Try spraying starter fluid on throttle body and then see.If it runs bit smooth or its same problem.If its running but smooth, with starter fluid sprayed, then its fuel pump issue.Get the fuel pump, filter, the injectors and o2 sensors checked.Also get throttle body cleaned, with throttle cleaner.---------- this should help.Thanks.Helpmech.

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