Firstly an apology for a TDI starting problems thread I know there are loads out there and I've read most of them and am still not able to get her to start reliably.
I will be as clear and detailed as I can.
I purchased her a month ago and when bought she was gutless as anything but started on the button. The first thing I did was give the engine a good service, Oil, Oil filter, Air Filter, Fuel Filter, Fuel Sedimenter and valve clearances, which 80% cured the issue of gutlessness.
About 2 weeks ago I got in her in the morning started her up no problem and drove 14 miles to the vets. When I went to come home again after approx 15 minutes she wouldn't start just kept turning over and over but no sign of catching. Popped the bonnet checked all the sensors where well connected and tried to start her again, nothing. Had a temper tantrum went and got a pasty and a coffee and when I came back she fired up as if nothing had been wrong. Until 2 days ago no problems.
4 days ago got in first thing and she started fine and drove 5 miles before filling up with Diesel from the pump, no bio or veg here. Went to start her up and she turned over for ages then fired, like a diesel with no glowplugs, but that shouldn't have been an issue with a warm engine anyway. Carried on my journey of 25miles and had to do several short trips around town to visit different stores. Each time she was stopped she got progressively harder to start until she just wouldn't. Had to wait for 2 hours for breakdown recovery and when they got there they checked all the vital fluids stuck a jump pack on and she fired first piston over centre. At that I must say I was seething with rage.
Drove home fine no problems at all. Next 2 days she was awkward to start when cold or hot but started in the end each time after lots of cranking and ran fine. Until the journey home yesterday. During that journey every so often the engine would sort of stall, then recover and be fine for another few minutes. No loss of power or smoke. Got home switched her off and went in.
Today decided lets try and sort this problem and do some naughty stuff. I had a EGR deletion kit arrive so that went on. I also removed the inlet manifold and gave it a clean out to get rid of marmite like crap in the inlet. Started her up after and she was fine. Started fine twice more and then started being awkward again. So I then fitted a new battery, as the old one was half the size of a standard battery and changed the glow plugs. No improvement whatsoever. If anything it got worse.
Now its at the point where it turns over and coughs but will not catch fully whatever. Turning the key whilst doing a octupus impression confirms the glow plug relay is clicking on and off with the light and the glow plugs are glowing as they should. When the ignition is on the injection pump is making a loud fast repeated clicking noise and on one cycle I heard a thunk noise from the vicinity and then it was prepared to start.
I can see one other fault that I will rectify tomorrow but I think that the fuel cut off solonoid is being intermittent and I suspect immobiliser issues of which im at a loss of how to fix. I am a mechanic but don't normally work on diesels as my area of expertise is classic cars, and those that are diesels don't have all this ECU controlled stuff on them.
So what do you reckon am I barking up the wrong tree.