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Author Topic: Vw sharan 1.9 tdi not starting  (Read 7995 times)

Offline Andyc

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Vw sharan 1.9 tdi not starting
« on: November 04, 2014, 07:01:24 PM »
Hi, need some help! I have a vw sharan 2002 1.9 tdi, for the last couple of weeks it has been a bit of a struggle to get it started first start if the day, once started it runs and starts fine for the rest if the day, took it for a service last week and since then the problem got worse, yesterday it took nearly 4 hours of constant trying to get it to start, so I took it to the local vw garage and arranged for new glow plugs to be fitted, they have called today and said even with them fitted the car will not start at all, it has been on the diagnostics and no faults are showing? But they have noticed that the new fuel filter that I had on at the service is not a proper vw one which could be the problem but won't know until we pay to get that done as well, which, after paying to get the glow plugs changed and finding that's not the problem, I am reluctant to believe it is the fuel filter as the car was playing up before the fuel filter was changed. I have googled the problem and seem to be getting many different suggestions so now do not know what to do for the best. Any help would be much appreciated. Thanks  :)

Offline Chrispb

  • Mindsaysyesbodysaysnono
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Re: Vw sharan 1.9 tdi not starting
« Reply #1 on: November 05, 2014, 04:25:25 AM »
Hi and  welcome5
Think I would change relay 109 first, what does the led on the drivers door do when your trying to start.

https://www.fordmpv.com/smf2/ford-galaxy-reference-library/galaxy-mk2-tdi-gaining-access-to-central-junction-box-fuses-relays/

Glow plugs on direct injection engines are mainly for post start emissions, they don't really need plugs for starting unless sub zero temperatures are prevailing.
2009 Kia Sedona GS In Black 2.9CRDI 183PS. 5 Speed Manual WAV.
2003 MK2 Galaxy Ghia In Solid Black 1.9 TDI 115PS. 5 Speed Automatic.

Upgraded Eberspächer booster heater  to independent heating with 7 day timer.

With VCDS lite (full version) need a code clearing or want to scan for faults in the north kent area, PM me.
All for a pint of Strongbow.

The FordMPV.com Forum - The free forum for questions and answers relating to the Ford Galaxy, S-Max and C-Max

Offline Andyc

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  • Model: Sharan Mk2
  • Spec: 02 1.9 tdi
  • Region: West Midlands
Re: Vw sharan 1.9 tdi not starting
« Reply #2 on: November 05, 2014, 06:18:15 PM »
According to the vw main dealer mechanics that have changed glow plugs and fuel filter, there isn't a relay 109 on the car? Phoned another vw specialist (not a main dealer) and they are saying it sounds like injector seals and that it's a common problem on the 1.9s although can't get it in til next week, any opinions?

Offline Mirez

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Re: Vw sharan 1.9 tdi not starting
« Reply #3 on: November 05, 2014, 06:58:36 PM »
Err no, injector seals on the 1.9 are not a common fail point at all - in fact, I don't think I've ever encountered a PD engine with one failed so be wary as that's an expensive job with little way of proving if it needed doing or not. On top of that, if it truly were the case, then the engine would run with the feeling of a misfire when you did get it started accompanied by a put-put-put noise - neither of which you are describing.

You almost certainly will have a 109 relay, its on the 3rd plate and has a high failure rate in build years up to 2003.
03 Ford Galaxy 1.9 TDI 115 Ghia in Spruce Green Metallic
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Offline insanitybeard

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Re: Vw sharan 1.9 tdi not starting
« Reply #4 on: November 06, 2014, 07:16:50 PM »
Something else worth checking when the fault occurs is that the lift pump in the fuel tank is running/priming the low pressure fuel system as it should be. Has the sealing O-ring on the connector that goes into the top of the fuel filter been replaced as well when the fuel filter was changed? If not there's a possibility that air could be entering the low pressure fuel lines.
« Last Edit: November 06, 2014, 07:18:25 PM by insanitybeard »
Always learning..... Often by mistakes!

Offline Andyc

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  • Spec: 02 1.9 tdi
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Re: Vw sharan 1.9 tdi not starting
« Reply #5 on: November 07, 2014, 11:16:21 AM »
Hi, thanks for all the advice, haven't tried anything else yet due to lack of time and money, but having a quick look this morning I have noticed a leak on what I think May be the top cover of the injectors? Would upload photo to determine location but don't know how to :-/ doesn't smell like diesel and it's not oil so unsure what it could be, any advice much appreciated although I know my description isn't brilliant, thanks

Offline Andyc

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Re: Vw sharan 1.9 tdi not starting
« Reply #6 on: November 07, 2014, 11:49:52 AM »
2995-02993-1
Hi, thanks for all the advice, haven't tried anything else yet due to lack of time and money, but having a quick look this morning I have noticed a leak on what I think May be the top cover of the injectors? Would upload photo to determine location but don't know how to :-/ doesn't smell like diesel and it's not oil so unsure what it could be, any advice much appreciated although I know my description isn't brilliant, thanks

Offline insanitybeard

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Re: Vw sharan 1.9 tdi not starting
« Reply #7 on: November 07, 2014, 12:29:02 PM »
The unit in the pictures with the small bore metal pipes coming out of it is the ABS modulator, the leak could be coolant leaking down from the header tank (the opaque plastic 'ball' above and infront of it), I'd certainly hope it's not brake fluid from the modulator/unions! I don't think either points directly to your problem though. Could it be diesel spilt from when the fuel filter was changed (which is at the extreme bottom left of your pictures with the rubber pipe going into it)?
Always learning..... Often by mistakes!

Offline Andyc

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Re: Vw sharan 1.9 tdi not starting
« Reply #8 on: November 14, 2014, 10:45:56 AM »
Have finally got round to changing the relay 109 yesterday, and the car started on the 7th attempt, which wasn't bad goin as the car had been standing for a week, although there was a lot of black stuff coming out of the exhaust. Took it for a long drive and was perfect, so kept my fingers crossed we had solved the problem! Tried to start it this morning, but no luck, so what's next? Thanks

Offline Chrispb

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Re: Vw sharan 1.9 tdi not starting
« Reply #9 on: November 14, 2014, 03:39:45 PM »
Can you confirm what the led light on the drivers door is doing when you are operating the starter but engine is not firing, also can you hear the fuel pump squelch type noise when first turning on ignition.
2009 Kia Sedona GS In Black 2.9CRDI 183PS. 5 Speed Manual WAV.
2003 MK2 Galaxy Ghia In Solid Black 1.9 TDI 115PS. 5 Speed Automatic.

Upgraded Eberspächer booster heater  to independent heating with 7 day timer.

With VCDS lite (full version) need a code clearing or want to scan for faults in the north kent area, PM me.
All for a pint of Strongbow.

The FordMPV.com Forum - The free forum for questions and answers relating to the Ford Galaxy, S-Max and C-Max

Offline Andyc

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  • Region: West Midlands
Re: Vw sharan 1.9 tdi not starting
« Reply #10 on: November 16, 2014, 12:09:30 PM »
Hi we have heard the squelchy noise on the few occasions that the car has started but most of the time the noise is not there, so we are thinking it's something to do with the fuel pump, but can hear the electrics buzzing every time, not sure what the led on the door is doing, mainly been flashing as usual but not checked with ignition on and now the battery is dead due to trying to start it. Will jump it today and check though. Thanks
« Last Edit: November 16, 2014, 12:13:14 PM by Andyc »

Offline Chrispb

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Re: Vw sharan 1.9 tdi not starting
« Reply #11 on: November 16, 2014, 01:28:01 PM »
There will be other noises from the heater flaps and motors, try not to confuse these with the squelch noise which is better heard with the door open.
Another check is to remove the outlet pipe on the fuel filter then switch on ignition, you should get a squirt of fuel lasting about a second, try and catch this in a container or have plenty of rag ready.
2009 Kia Sedona GS In Black 2.9CRDI 183PS. 5 Speed Manual WAV.
2003 MK2 Galaxy Ghia In Solid Black 1.9 TDI 115PS. 5 Speed Automatic.

Upgraded Eberspächer booster heater  to independent heating with 7 day timer.

With VCDS lite (full version) need a code clearing or want to scan for faults in the north kent area, PM me.
All for a pint of Strongbow.

The FordMPV.com Forum - The free forum for questions and answers relating to the Ford Galaxy, S-Max and C-Max

Offline Andyc

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  • Spec: 02 1.9 tdi
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Re: Vw sharan 1.9 tdi not starting
« Reply #12 on: November 16, 2014, 11:14:52 PM »
Hearing the squelchy noise once in a while, and fuel is going through when it's heard, there is a buzzing noise too (every time) which must mean the electrics are working, but no start :( also when trying to start the electric window came down??? Confused :-/ am still googling, and have come across fuel cutoff solenoid but can't seem to find out where this is located?  Also linked to diagnostics again today but still nothing :( as I have changed relay 109 I am wondering also if there is another relay for the fuel pump?  Any help much appreciated, thanks :)

Offline insanitybeard

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Re: Vw sharan 1.9 tdi not starting
« Reply #13 on: November 17, 2014, 09:47:24 AM »
There is another relay for the fuel pump, I would presume it's the same for an '02 plate, there's some discussion about it here. I think relay 53 may have been responsible for an intermittent starting issue I had (and may still have but since I messed around with the relay it's not re-occurred!)
Always learning..... Often by mistakes!

Offline Andyc

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Re: Vw sharan 1.9 tdi not starting
« Reply #14 on: November 26, 2014, 11:28:23 AM »
3025-0* image.jpg (1592.71 kB. 3264x2448 - viewed 2590 times.)

Offline insanitybeard

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Re: Vw sharan 1.9 tdi not starting
« Reply #15 on: November 26, 2014, 11:35:18 AM »
That's a broken air-con refrigerant pipe, that will explain why your air-con doesn't work but won't affect engine starting/running!
Always learning..... Often by mistakes!

Offline Andyc

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Re: Vw sharan 1.9 tdi not starting
« Reply #16 on: November 26, 2014, 05:42:09 PM »
Back again lol! Have looked at the cam belt and noticed that it's fraying down the one side, does anyone know if this could cause it to slip and not start?

Offline insanitybeard

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Re: Vw sharan 1.9 tdi not starting
« Reply #17 on: November 26, 2014, 06:07:10 PM »
Fraying on a cam belt is never a good sign, how bad is it? Having said that, as they are toothed they don't tend to slip (though the rubber teeth can be sheared off of the belt backing which will throw the timing out), instead they tend to just snap which can result in valve to piston contact and major engine damage. If the tensioner fails or the water pump or idler bearings fail then this can allow the belt to lose tension and send the timing out as well, I'd recommend checking all of this, if the timing is out due to any of the above you could be looking at imminent major damage, assuming nothing's happened already.

If the timing is out then yes, that could cause it not to start. The important thing is to find out if it is and why!
« Last Edit: November 26, 2014, 06:08:38 PM by insanitybeard »
Always learning..... Often by mistakes!

 

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