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[Solved] VW Golf 4 / 1.9TDI / 90km - After firing up I don't even work and kick.

sidorboss 14559 16
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Why does my VW Golf 4 1.9 TDI run rough and smoke on a cold start, but become normal after about 2 minutes?

The thread points to internal engine damage rather than sensors or glow plugs: the most likely cause discussed is a bent connecting rod or other piston/liner damage that lowers compression when cold, so the engine kicks and smells of unburned fuel until it warms up [#16655387] [#16656734] The recommended check was to measure compression on a cold engine through the glow plug holes; the posted cold values were 25.5, 27, 24.5, and 27.5, but later the owner noted damaged-looking glow plugs with chipped/burned ends [#16725521] One early alternative was a stuck injection-pump adjuster caused by swarf, so the pump plug/adjuster was also suggested for inspection [#16655095] In the end, the reported fix was engine replacement because one piston was found pulled sideways against the cylinder wall [#17869345]
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  • #1 16655049
    sidorboss
    Level 9  
    I warmly welcome,
    This is my problem that I have been struggling with for several months. Car as the title, 1.9 TDI engine. While driving and overtaking, he suddenly jumped in and pulled like a young bull forward, after which everything returned to normal and the car reached its destination. On the next May day (plus temperature), in the morning on the cold engine appeared uneven engine operation (as if the gar did not smoke) and kicking (the stench of unburned oil). After 2 minutes everything returns to normal, the car walks evenly, does not kick, it gathers normally.
    Ever since then on a cold heap. Once more or less once more. What I did: replacing the temperature sensor because it was dead, candles checked with an ohmmeter and they are ok, the injection tips are replaced and the injections checked, which are ok. Oil is not depleted, the fluid is not contaminated with oil. People write that the turbine sucked in and the car went but now it goes like a chisel after warming up and it does not kick. As if the turbine and power would have run out. Please help. Tomek - Wroclaw
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  • #2 16655060
    sulof1601
    Level 26  
    Hello. According to me, the problem lies on the side of the pump adjuster unless you have a crammed BOX.
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  • #3 16655079
    sidorboss
    Level 9  
    How can you please more clearly what is this BOX. I would add that I seem to hear a slight metallic clatter, equal to the rotation. Oh. There was a pump man at my place and he said that the jump could be cut off.
  • #4 16655095
    sulof1601
    Level 26  
    It was not the pump that got stuck, but the pump adjuster as a result of accumulated swarf. The injection pump comes out with a cable with an oval plug, see if this plug is not attached as if a splitter at the end with a plastic box.
  • #5 16655387
    adam7009

    Level 41  
    You have bent connecting rods after this action
    sulof1601 wrote:
    While driving and overtaking, he suddenly jumped in and pulled like a young bull
    Company Account:
    AUTO-ELELEKTRONIK AB
    Linowiec, Lisewo, 86-230 | Tel.: 697XXXXXX (Show)
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  • #6 16655430
    sidorboss
    Level 9  
    The car went on vacation and I will have it in a week, I will check it as you say. Mr. Adam7009 - if I have bent connecting rods, why does the car walk after 2 minutes normally?
  • #7 16655617
    adam7009

    Level 41  
    As the engine warms up, combustion improves and stops smoking.
    Maybe only one connecting rod bent, I don't know ...
    Company Account:
    AUTO-ELELEKTRONIK AB
    Linowiec, Lisewo, 86-230 | Tel.: 697XXXXXX (Show)
  • #8 16656175
    sulof1601
    Level 26  
    How would the connecting rod be bent? first of all, it would have to suck in oil, secondly, the crooked connecting rod has a much lower compression ratio and would kick white non-stop. The engine temperature will not change anything here.
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  • #9 16656200
    adam7009

    Level 41  
    sidorboss wrote:
    While driving and overtaking, he suddenly jumped in and pulled like a young bull forward,
    then he sucked in oil.
    90% of cases end this way, i.e. with a bent connecting rod. The mechanic now I see you should know after all.
    Company Account:
    AUTO-ELELEKTRONIK AB
    Linowiec, Lisewo, 86-230 | Tel.: 697XXXXXX (Show)
  • #10 16656209
    sulof1601
    Level 26  
    I only agree with the angle of this oil since it claims that the turbine works without a problem? It just wonders me ......
  • #11 16656621
    sidorboss
    Level 9  
    Exactly. If it is connecting rods, then through the turbine, which runs smoothly, there is no decrease in power and oil would decrease. And the smell of unburned oil - that is, something that comes in contact with oil.
  • #12 16656734
    matimon22
    Level 25  
    Unfortunately, you won't fool yourself. For 100% crank - definitely one. It is possible that it was not the turbo that caused oil to enter the combustion chamber. Unscrew the candles and check the compression on cold and you will already know.

    sulof1601 wrote:
    How would the connecting rod be bent? first of all, it would have to suck in oil, secondly, the crooked connecting rod has a much lower compression ratio and would kick white non-stop. The engine temperature will not change anything here.


    Well, that the temperature of the engine has a lot to do here (too cold it will kick unburned oil, on warm it will be ok). I see that you have not processed many such cases.
  • #13 16657308
    sidorboss
    Level 9  
    Are you sure you want to check compression on a cold? Is it enough to unscrew the candles when checking? I heard that the injection rail should be removed.

    And since the connecting rod, why did he never bury and kick when riding in white or gray there?
  • #14 16657598
    adam7009

    Level 41  
    take it, don't fool yourself that you will change the candle or any other sensor and it will be ok
    Company Account:
    AUTO-ELELEKTRONIK AB
    Linowiec, Lisewo, 86-230 | Tel.: 697XXXXXX (Show)
  • #15 16658146
    matimon22
    Level 25  
    sidorboss wrote:
    Are you sure you want to check compression on a cold? Is it enough to unscrew the candles when checking? I heard that the injection rail should be removed.

    And since the connecting rod, why did he never bury and kick when riding in white or gray there?


    You have to unscrew them because you check the pressure through them. What rail are you talking about? You have a motor on a VP pump
  • #16 16725521
    sidorboss
    Level 9  
    I unscrewed the candles, disconnected the fuel and checked the pressure on a cold engine:
    1 - 25.5
    2 - 27
    3 - 24.5
    4 - 27.5
    But I will add that after removing the candles, 3 of them are burned at the end, as if chipped, fourth like new.
  • #17 17869345
    sidorboss
    Level 9  
    I replaced the candles, made injections, injection angle and nothing. I ended up replacing the engine. The reason - one of the pistons was pulled out sideways on the wall so there is nothing to worry about, it's a waste of money. But all the new parts were suitable for the donor engine.

Topic summary

✨ The discussion revolves around a VW Golf 4 with a 1.9 TDI engine experiencing performance issues, particularly rough idling and kicking upon starting with a cold engine. Users suggest potential causes including a faulty pump adjuster, accumulated swarf in the injection pump, and possible bent connecting rods. The author has replaced the temperature sensor, checked glow plugs, and replaced injection tips, but the problem persists. Compression tests reveal varying pressures across cylinders, with one spark plug showing signs of damage. Ultimately, the author replaced the engine due to severe piston wear, indicating significant internal damage.
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FAQ

TL;DR: Cold-start misfire and white smoke on a Golf 4 1.9 TDI often trace to mechanical damage; one owner measured 24.5–27.5 bar compression and later found a scored piston. “90% of cases end this way.” [Elektroda, adam7009, post #16656200] Why it matters: This FAQ helps Golf 4 1.9 TDI owners diagnose rough cold idle, smoke, and sudden power surges without wasting parts.

Quick Facts

What are the classic signs of cold-start trouble on a Golf 4 1.9 TDI?

Common signs include uneven idle for 1–2 minutes, white smoke, and a raw oil smell on first start. After a short warm-up, idle smooths and power returns to normal. This pattern points beyond glow plugs to fueling or mechanical health. Record the duration, smoke color, and ambient temperature for diagnosis. “Uneven engine operation and the stench of unburned oil” are primary clues from owners. [Elektroda, sidorboss, post #16655049]

Could a sudden power surge mean oil ingestion and a bent connecting rod?

Yes. A diesel that suddenly “pulls like a young bull” can run on engine oil, over-rev, and bend a rod. One contributor states, “90% of cases end this way,” highlighting the risk. If cold-start smoke persists and compression drops on one cylinder, inspect for rod damage. Avoid driving hard until compression is checked. [Elektroda, adam7009, post #16656200]

How do I check compression on a 1.9 TDI with a VP pump?

Use a diesel gauge through the glow plug ports. 1) Remove glow plugs. 2) Disable fueling. 3) Crank and note pressures per cylinder when cold. This engine uses a VP rotary pump, not a common-rail rail. Comparing cylinders helps spot one weak hole that misfires cold. Document values and test conditions. [Elektroda, matimon22, post #16658146]

What numbers did the OP measure for compression, and what do they suggest?

Measured cold values were 25.5, 27, 24.5, and 27.5 bar. The spread shows one or two lower cylinders. A single notably lower cylinder increases suspicion of mechanical wear, ring or bore issues, or a bent rod. Re-test warm to compare stabilization. Keep the results with date and ambient temperature for your mechanic. [Elektroda, sidorboss, post #16725521]

What is the ‘BOX’ people mention on the injection pump?

It’s a plug-in tuning box that intercepts the VP pump harness at the oval connector. It alters fueling signals to increase torque. Aged boxes or poor connections can cause erratic fueling, surging, or rough idle. Check for any splitter and plastic module on the pump plug and remove for testing. [Elektroda, sulof1601, post #16655095]

Can the VP pump’s quantity adjuster cause rough cold running?

Yes. Swarf contamination can stick the quantity adjuster, upsetting idle fuel delivery. Symptoms include inconsistent cold fueling and surging. Inspect the adjuster circuit and wiring at the pump connector. Cleanliness and proper calibration are critical before replacing major components. Rule out add-on boxes first. [Elektroda, sulof1601, post #16655095]

Why would smoke reduce after two minutes if a rod is bent?

As the engine warms, combustion efficiency improves and cold misfire smoke can diminish, masking damage. A slightly bent rod lowers effective compression, most noticeable when cold. Warm operation can feel “normal,” yet damage persists. Do not ignore a consistent cold-only miss combined with earlier runaway-like surge. [Elektroda, adam7009, post #16655617]

I replaced glow plugs and set injection timing. Why didn’t it fix the cold miss?

Because the root cause can be mechanical. In the discussed case, new glow plugs, injector service, and timing did not help. Teardown revealed a piston scuffed sideways in the bore, and an engine swap solved it. Parts-chasing without diagnosis wastes time and money. “It’s a waste of money.” [Elektroda, sidorboss, post #17869345]

Does a healthy turbo rule out bent rods or oil ingestion?

No. A turbo can appear to operate normally later, yet a past oil-ingestion event may have already caused damage. If you experienced sudden uncontrolled pull and now have cold smoke and uneven idle, perform compression testing before assuming the turbo is innocent or guilty. [Elektroda, adam7009, post #16656200]

What does white smoke with an oil smell indicate at cold start?

White smoke with an oil smell indicates unburned fuel or oil due to poor cold combustion in one cylinder. This can stem from low compression, fueling deviations, or cylinder wear. Track duration and temperature; persistent two-minute episodes point to deeper issues than plugs alone. [Elektroda, sidorboss, post #16655049]

How do I quickly rule out a tuning box fault before deeper work?

Visually inspect the VP pump’s oval plug. If you see a splitter and small plastic module, remove the box and restore the stock connection. Road-test from cold and note if symptoms change. Any change implicates the box or its harness. Keep the module out until fully verified. [Elektroda, sulof1601, post #16655095]

What edge case should I know before spending on sensors and injectors?

An engine can pass basic checks and still have cylinder wall damage. In the case discussed, only teardown confirmed a piston pulled sideways on the bore. The owner replaced the entire engine; previously bought parts were reused on the donor. Consider compression and borescope checks early. [Elektroda, sidorboss, post #17869345]

Is temperature sensor replacement enough when cold-start issues persist?

No. A failed coolant temperature sensor can worsen cold fueling, but fixing it will not correct mechanical defects. If symptoms persist after sensor and glow plug checks, escalate to compression testing and inspection of pump controls or internal engine condition. Avoid repeated parts swaps. [Elektroda, sidorboss, post #16655049]

What’s a VP (rotary) pump in this context?

It’s the distributor-type injection pump used on this 1.9 TDI, controlled electrically with a quantity adjuster. It lacks a high-pressure common-rail. Diagnostics therefore focus on the pump harness, adjuster function, and mechanical health of the engine rather than a rail and injectors. [Elektroda, matimon22, post #16658146]

3-step how-to: baseline a cold-start misfire on a VP-pump TDI

  1. Remove glow plugs, disable fueling, and record cold compression per cylinder.
  2. Inspect the pump plug for a tuning box; bypass and retest cold.
  3. If one cylinder is low, add a borescope exam before buying parts. [Elektroda, matimon22, post #16658146]
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