1.9 tdi won't rev, smoke, stalls

[Transporter]

How was it running before it started to misbehave?


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[Tangles553]

This is where I'm at...



Had everything off to do timing, found I couldn't turn the camshaft at all with any sane application of strength. That didn't seem right, so i had the tandem pump off to see if it was binding. That was fine, so I figured I'd pull the rocker cover. Lots of condensation inside... Not sure how or why, although the sump oil looks fine there is milkyness under the oil cap.

I already had a spare head gasket and bolts here so figured it wasn't much extra work to simply do it and know it's done right (previous owner replaced the head and did a questionable job)



Took the injector rockers off and the cam spins freely so I guess the injectors just require a lot of torque to get pumping. I'm swapping them out so will see if there's any difference when it goes back together

Camshaft is like new, as it should be, it IS new

How was it running before it started to misbehave?

Running fine, then the turbo blew and the head was replaced due to it slowly using coolant. Put it all back together, now this.

[Transporter]

When you’re at it, before you fit the cyl. head back on, check the TDC of each piston making sure that all are at TDC.


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[saabman]

Just wondering if it appeared after having large number of parts pulled out to replace the turbo and do the head is it possible something as simple as a vacuum line is connected wrong?

I know I'm guilty of such mishaps

or parts from the disintegrating turbo lodging where they shouldn't?

[Tangles553]

When you’re at it, before you fit the cyl. head back on, check the TDC of each piston making sure that all are at TDC.

Do you mean check they all reach the top of the stroke? ie no bent rods?

Just wondering if it appeared after having large number of parts pulled out to replace the turbo and do the head is it possible something as simple as a vacuum line is connected wrong?

I know I'm guilty of such mishaps

or parts from the disintegrating turbo lodging where they shouldn't?

Maybe, I'm going to hate myself if I find something like that wrong haha but I have been over all that in detail and can't find anything wrong, although not that I am able to find a vacuum diagram for the BKC golf

Only the turbo seal failed, nothing broke

[Transporter]

Do you mean check they all reach the top of the stroke? ie no bent rods?

Yes, that’s what I meant.

[Tangles553]

Yes, that’s what I meant.

All good, protrusion looks normal

How difficult should it be to rotate the camshaft with the injectors in? I'm feeling a lot of resistance

[Transporter]

All good, protrusion looks normal

How difficult should it be to rotate the camshaft with the injectors in? I'm feeling a lot of resistance

There’s quite a bit of resistance from these unit injectors.

[Tangles553]

Thought I'd come back here to update the cause.

Issue was the injector seals / o-rings between the fuel supply and fuel return galleries in the head. Clamping off the return line so the fuel couldn't return to the tank fixed the issue immediately, taking the vice grips off the hose caused it to stall out again.

Easy fix at least!