cold start smoke out, 1981 240 DL motor

Nordic Tug · Post by **Nordic Tug** » 13 Aug 2007, 11:01

I have a Volkswagon Pathfinder diesel in an 81 Nordic Tug. The motor was used in Volvo 240 DL cars from the early to mid '80's. The problem is hard starting and lots of smoke when it's cold. When warmed up it is smooth and has very little smoke. It doesn't burn much oil. The fuel injection pump belt was replaced, along with the timing belt and glow plugs. What system is used with the injection pump to aid cold starting? How do I know if the mechanic got the timing of the pump just right? How is that checked?

Post by **billofdurham** » 13 Aug 2007, 12:57

Welcome to Matthew's Volvo Site.

The glow plugs are there to assist with cold starting. They warm the inside of the compression chamber thus raising the air temperature and making starting easier. Although you have had yours changed you have the symptoms of at least one bad glow plug.

The symptoms of a bad glow plug are hard starting in cold weather, missing, rough idling and lots of white smoke until the engine warms up.

To check your glow plugs:

http://www.accuratediesel.com/gplugs.htm

At the moment I can't answer about the timing of the injection pump but I shall keep looking.

Hope this is of some help.

Bill.

Nordic Tug · Post by **Nordic Tug** » 13 Aug 2007, 14:35

If the injection pump timing is off the engine should run poorly even when warmed up, correct?

Post by **billofdurham** » 13 Aug 2007, 15:24

Correct.

Bill

Nordic Tug · Post by **Nordic Tug** » 23 Aug 2007, 08:15

I found a reference in an engine manual to a lever that will disable the cold start mechanism so the pump can be timed correctly while cold, then enabled to advance the timing of the injection pump about 5 degrees while cold. I've looked all over for the lever and can't find it. The lever is supposed to be between the pump and the block, toward the back of the pump.

Is there any other way the cold start system can be disabled on these pumps, like maybe a button or electronic system on older engines? Does anyone have experience with this cold start disabling device?

Post by **billofdurham** » 24 Aug 2007, 12:12

The only reference I can find to the VW Pathfinder diesel is its use as a marine engine. Unfortunately none of the things I have read go into detailed mechanics.

I have asked two Volvo techs, who are very helpful, and they can't remember ever working on one, so they are now off my Christmas card list.

The only thing they can suggest is that you extend your search to include boats as they were a popular unit in that area.

Bill.

A.Baker · Post by **A.Baker** » 14 Oct 2007, 21:11

What color is the smoke? White is a cold fuel burn, Blue is oil, Black is too much fuel or not enough air.

Nordic Tug · Post by **Nordic Tug** » 15 Oct 2007, 18:29

The fuel seems white. There isn't any oil consumption. When the engine is warm the smoke clears. I have a service bulletin that indicates a lever on the inside of the fuel injection pump which should be rotated 90 degrees toward the bellhousing to disable the cold start system so the timing can be done correctly but I've used an inspection mirror and LED flashlight to do a really close detailed inspection and I can't find any lever. Last year the fuel injection pump belt was replaced, along with the timing belt, fresh water pump, raw (salt water) pump and all glow plugs. The mechanic said he knew how the timing was done for the Volvo 240 DL but he couldn't find the cold start system either, so he did the best he could. I'm looking for an old timer marine mechanic in the area to help out. It's really frustrating. If I win the lotto I'll just turn the motor into a new anchor and put a good modern diesel in.

wojeepster · Post by **wojeepster** » 16 Oct 2007, 18:09

have you been having this problem ever since he timed it? If not it cannot be the timing and find your bad glow plug.

A.Baker · Post by **A.Baker** » 21 Oct 2007, 21:51

Because the smoke is white there is a heat issue in the cylinder not letting the fuel burn completly. Cummins had this problem in the mid 80's. They used a bunch of junk to try and fix it. It sounds as though you have the same problem. The good part is you have a glow plug system! Here is a quick and cheep fix. Go to Ford and get a glow plug relay for a 7.3 NONE Powerstroke engine and conect that to the glow plugs and use an on off switch to control the ground side of the relay. You will have to remember to shut it off after after the engine warms though. Or if you can run the ground through a temp. switch in the blocks water jacket. Send me your E-Mail or fax # and I will send alog a schematic to wire it in. Hope this helps.
A.Baker
P.S Has the compression on all cylinders been done? Have the injectors been poptested and reset? That may also cure the problem. Do what ever fix is need soon. Befor the engine fuel washes a cylinder and then it will be an anchor.