Brake Vacuum Problem On 1.9tdi

[Guest JaseB]

Hi, This is the first time I have ever posted on a Forum so please be patient.

 

First of all I would like to say I have a 'W' 2000 reg 1.9TDI (110) Zetec. I do have an aftermarket Chip on board (30% BHP and 40% torque) plus K&N Filter. The gain is not proved but it still puts a smile on my face at the lights (With the caravan).

 

Late last year I was giving it some againts a Golf TDI (Boys and thier toys) when, everything slowed up and I was breaking reasonably hard all of a sudden, I noticed lac of braking force similar to fading, anyway calmed down a bit and tried to get the brakes to do the same, The only way I could get this to happen was by tapping the brake pedal continuously then all of a sudden no servo assist, anyway Christmas came and went and I thought I better get something done ready for the new Camping season.

 

I took it to a main Ford dealer in Derby (opposite Pride Park) and they said they want a minimum hour for diagnostic (

[seatkid]

If the "performance goes" (no turbo boost) along with your brakes going hard then you have a vacuum leak. The vacuum works the brakes and the turbo boost control.

 

1. Look in the footwell at the rod going into the footwell. There is a rubber flap valve that sits over the end at the servo. If this is damaged or distorted, it leaks air. maybe something trapped in there.

 

2. Check through all the vacuum piping and joints - replace all suspect bits. The vacuum pipe to the servo unit itself is known to split.

 

3. Its then down to the servo itself - but I think this is unlikely you'll get to this step....

[Guest JaseB]

Thanks Seatkid for the fast reply, I will get my head in ASAP, but excuse by ignorance but are we talking in engine bay or Cabin for the rubber flap,

 

Also I have not noticed the turbo loosing power kick in probably due to me braking

not accelerating I will try to combine a bit of both on the way to work tommorow

 

I have an independant garage and Ford say all pipes are good but my confidence in garages is low at the moment

 

Once again cheers, JaseB

[Masked Marauder]

A good test for the servo is to run the engine at a fast idle to get the vacuum up then switch off the engine.

 

Pump the brakes until the vacuum is gone then hold down the brake pedal and start the engine. If the pedal falls then the vacuum is fine.

 

How did you get your BHP?Torque figures up so high btw?

[Guest JaseB]

Yes it does this fine, but if you pumpthe brake you run out of vacuum, not quuite as fast as if the engine is running, if you rev the engine it will then replenish and braking assist is resumed, The main dealer said they would accept what is happening and it would fly through a MOT but its not his Wife and kids cominf down the hills in Mid Wales being pushed by a caravan

 

Thanks for the input

 

JaseB

[seatkid]

Thanks Seatkid for the fast reply, I will get my head in ASAP, but excuse by ignorance but are we talking in engine bay or Cabin for the rubber flap,

Cabin, in the footwell by the pedal.....

 

 

Pipes can look Ok but still be split....

[Guest JaseB]

Sorry, I missed the question about the BHP & Torque, The box you can fit advetise these figures how true they are I don't know, do a search for HH tuning in a search

engine I think theirs offer about 25 % but if you have a K&N on as well they clain 5% power. I would like to get it on a rolling road but I'm scared they would laugh when I'd say its the galaxy over there. so I will just keep playing with older Audi A3's, knowing if they pull away they have done the same.

 

Plus you actually gat better fuel consumption if you can stop playing as you hav higher torque you can change gear earlier, FANTASTIC.

 

On another note I get Zero oil consumption on 10000 miles and I'm just about to clock 100,000 . I cannot fault this car as long as I can get the brakes done.

 

I think there is a company called chocolat box as well that do these plug in units,

 

Email me direst if you want any Further cahat on this subject, I will get back to you Tomorrow as I'm off to bed now (4.30am start)

 

Thanks again JaseB@bradman.org.uk

[Guest JaseB]

Seatkid,

 

Yes I am tempted to change all pipes as I have had a free Vacuum pump, I think the cost could be alot less,

 

Have you any thoughts on the one way valve, or will this just FAIL ??

 

JaseB

[Guest marcusheawood]

...I'd be really surprised if they had actually changed the vacuum pump (just tested it)... ;)

[Guest JaseB]

They replaced it all right as I have the invoice. I argued they should have tested it prior to changing it, so (Thats why I payed

[Masked Marauder]

Well clearly it is making a vacuum. So next stage is to check the hoses to the vacuum sphere and the sphere its self. It's job is to store a vacuum in the system.

[tim-spam]

If the brakes are working OK on the first application, the vacuum pump is (and the old one almost certainly was) working. Your problem is almost definitely a leak, and your dealer has unnecessarily replaced the vacuum pump.

 

On another point, a K&N air filter is not a very good idea, as it could lead to contamination of the MAF. It will add nothing to the performance of the engine.

[Guest JaseB]

Why is the k&n such bad news I thought they increased airflow and surely a TDI requires masses of airflow, especially as the aftermarket chip increases fuel input,

I admit it does blow alot more black stuff when flooring it but thats sureley just unburnt fuel, the k&n has reduced this smoke.

 

Do k&n allow larger particles through ?? thus allowing contaminants to affect the MAF ??

[Guest vr6galaxy]

K&n's use oil as as a trapment system, this oil gets sucked up the inlet pipe and can contaminates the MAF :D not a good idea!

[Guest JaseB]

OK, CHEERS FOR THAT, IF I GET THE BRAKES SORTED I WILL SWAP IT.

[Guest vr6galaxy]

Pardon :D turn down the volume a bit we can HEAR you ok :D

 

there are a couple of performance filters available that dont use pre oiled filters :D one company Green Cotton Filters do a kit for the TDI Galaxy :D either a replacement element for the OE air box or an induction kit :o

[Guest JaseB]

Cheer's for that matey, sorry for shoutin I.m at work and are only allowed to use CAPS on the drawings, autopilot again !!!!!

[Guest JaseB]

Hi, just come back from Ford after having the Vacuum pipes overhauled, and guess what ? No Change, the vacuum still exhaust's itself after 8 or 9 pumps with the engine on tickover.

 

They said the only thing left in the system is the servo itself which I already knew.

 

They did say they have a "FORD SUPER TECHNICIAN" coming on the 27/2/2006 and he can look at it for me, (I presume he's the one with his underpants on the outside ). My only hope is that if he say's it is the sevo and it does'nt rectify the problem I might get my money back again.

 

Now to the Question..............

 

I have just received word from an old work pal that his Galaxy does the same ('R' 1.9TDI Ghia ) while doing 30-40mph if he dips his clutch and keeps tapping the brake pedal repeatedly (Without trying to stop the car) The servo runs out and then recouperates after a few seconds.

 

Bingo !!!!! exactly the same as mine,

 

Is this an inherant problem with the Mk1 TDI's ?????

 

Could anyone one else try this and report, before Ford say 'Give me all your money"

 

Cheers JaseB

 

PS Please make sure you have a clear bit of road (Behind you)