300tdi EDC - Overheating / Juddering

Bit of an odd one,

1995 300tdi EDC Auto, ran fine for a good couple of thousand miles, within the past month it occasionally starts to run a bit **** and start holding back, usually seems to be when cruising, I'll be doing a steady 65 on the flat and it'll start slowing down and temperature gauge goes up right towards the red....kick down and it starts juddering like mad. If I let it slow down to around 50mph the temp gauge will settle back down to the middle....hold it there for a minute or so, and you feel it go back to normal and can return back to normal speeds again!

This seems to happen more and more now, and now I've started using the car to get to work I need to sort it! Recently done a bit of a service (oil & filter, coolant, air filter, de-EGR, fuel filter) - and I run it on 50/50 veg/diesel but it has done it running on 100% diesel too.

First thought was some sort of fuel issue but I can't work out why that would make the temperature shoot up? So far I need to check: sedimentor, thermostat, lift pump, injectors? Anything else? Anyone seen this before?!

I don't think it's related but I have slightly dodgy brakes that pull either way unless you have the steering wheel pointed the right way (I sort of got used to it having driven a series for god knows how long) - I think this is down to the panhard rod bushes as the steering feels pretty loose generally, and I don't think this can be related - can it?

After an eventful journey to work I'm now pretty sure it's transmission related. Started up this morning and had a clicking/buzzing noise from the gearbox area, almost sounded like electrical sparking. Thought it was the carrier bag with my dinner in at first!

Then on the hill going up the M69 (it always seems to be on a hill?) the usual problem started, the clicking got louder, and it lasted for ages and didn't seem to get better. Ditched it on the hard shoulder as I was scared of a prop shearing or something. Checked the props for play and they seemed fine. Decided to carry on and it cleared about a minute later...

Couldn't immediately 'feel' anything wrong, but there were a couple of oil drips from the bellhousing to flywheel housing join. The boss at work has suggested torque converter and I'm starting to think that too (engine/box just turned 185k so had a good run!)

Any way to check for sure? New box?

you can drain some oil out black is burnt clutch pack ,silver sheen is often broken epicyclic hub ,clicking can be fault with park brake mechanism or cracking around t/c bolts can be seen by removing access plate ,are you sure wheel bearings and cvs are good ,over heating ,check rad is hot all over core surface systems full not just header tank

I had similar problems a while back mine was sediment filter and split fuel pick up pipe on top of the tank hope this helps

Managed to get home, did it again on the way back for a good while, always seems to happen when going up hills so definitely suspecting sedimentor. Had no noise from gearbox this time.

Just having something to eat then going to check everything and will report back...

Had a poke and hope....

Stuck my head underneath and someone's already bypassed the sedimentor with a piece of pipe. Checked the fuel filter (replaced recently) and poured the contents into a bottle, seemed OK.

Had a look at all the pipework, the injector spill pipes looked a little bit rough, ones been replaced with normal pipe without an over braiding and two circlips, the other two had a bit of cracking at the end. Had a length of new pipe from when I 200di'd the series so replaced the lot.

One of the breather pipes (not the one that goes through the cyclone, the normal black pipe) had a big split that had been covered in electrical tape and lifted off, so I re made it with more layers of electrical tape as that's all I had!

The coolant was a bit low, header tank was empty! And the rad was low. Have refilled and bled it all through but will keep a close eye on it.

The only odd thing I did notice was that someone has put non return valves on the fuel feed/return pipes to/from the tank, I've never seen this fitted standard, can anyone confirm before I bypass it? Just seems like another thing to go wrong so would rather not have them if I don't need them.

I'm going to order a new lift pump anyway I think, it has been replaced at some point by the looks of it, but god knows if it's 'blue box' or not.

Got a site visit tomorrow 20 miles away so fingers crossed it gets there!

Another update....

Did about 60 miles today, never once got hot, never once went all juddery, so something that I done must have helped!

Only thing is it's developed an allergy to hills, goes slow as anything now, so gone back to suspecting the lift pump or fuel supply pipe. I doubt the non return valves are helping so I'll more than likely take them off too!

Paddocks order currently contains lift pump and polybush kit, I'll have a look at hubs and brakes and stuff and see whats going on there and bang an order in as MOT is due next month too...

I'll keep it updated once again with any developments

TheKeymeister said:

Had a poke and hope....

The coolant was a bit low, header tank was empty! And the rad was low. Have refilled and bled it all through but will keep a close eye on it.

The only odd thing I did notice was that someone has put non return valves on the fuel feed/return pipes to/from the tank, I've never seen this fitted standard, can anyone confirm before I bypass it? Just seems like another thing to go wrong so would rather not have them if I don't need them.

Got a site visit tomorrow 20 miles away so fingers crossed it gets there!

Click to expand...

I'd keep a very close watch on the coolant if I were you - most of the symptoms you describe COULD indicate a blowing or blown head gasket.

Keep checking that coolant...............................

Aye that's been in the back of my mind too...I'll keep checking it, and if it doesn't get better ill go and get a compression test

TheKeymeister said:

Aye that's been in the back of my mind too...I'll keep checking it, and if it doesn't get better ill go and get a compression test

Click to expand...

Or get a 'sniff' test to see if there is exhaust in the coolant and coolant in the exhaust gas.

Think I've cracked it

Bought a new Delphi lift pump and went to put it on today, dismantled the fuel pipe that had been bodged onto it, and found a little surprise wedged in the non return valve...

[/IMG]

That's a piece of the solid plastic fuel pipe, presumably from where it had been cut to bodge the non return valve on....not sure if I should have, but I've ditched the non return valve and put a piece of clear hose on, and fitted the new lift pump, and (so far) it drives like a dream!

Coolant seems to slowly drop, but it seems more like a leak somewhere rather than a head gasket issue, as its a tiny amount and not often...

Nice one ! thanks for giving us the end result