Author Topic: Major trouble (Read 8350 times)

travisdj · « **on:** September 06, 2007, 07:23:16 pm »

So I had to replace the ip on my 1991 Jetta 1.6D n/a. Got it on, timed and fuel to the injectors. When it will actually crank it smokes white, then the smoke stops. Give it some go pedal and it dies. My buddy has been helping me and he is a diesel mechanic, we are both baffled. We have put a good 15 hours into this thing trying to get it to run again. I just don't know what to do. Any help is appreciated.

jtanguay · « **Reply #1 on:** September 06, 2007, 07:45:18 pm »

maybe to better help, what have you and your diesel mechanic friend done to try and resolve this? such as, check if timing is 180 degrees out, bubbles in fuel (fuel related issue)?

to me, it sounds as if the pump just isn't set for enough fuel. what timing did you set it at? 1.00mm should be perfect. try messing around with the fuel and residual fuel screws, but make note of any change by keeping track of the number of 1/4 or even 1/8 turns. how did the car run before? has the fuel filter been changed recently?

travisdj · « **Reply #2 on:** September 06, 2007, 07:55:18 pm »

Sorry for not giving more information. We have tried changing fuel settings, changing timing, timing was rechecked last night. "Idle screw" is all the way in, but when you give it ANY throttle it dies. You have to push the throttle arm in the opposite direction that it should turn to get it to crank. How would it even be possible for the timing to be 180 out you can only fit the tool in one hole. I am at my wits end with this thing.

jtanguay · « **Reply #3 on:** September 06, 2007, 08:16:13 pm »

Quote from: "travisdj"

Sorry for not giving more information. We have tried changing fuel settings, changing timing, timing was rechecked last night. "Idle screw" is all the way in, but when you give it ANY throttle it dies. You have to push the throttle arm in the opposite direction that it should turn to get it to crank. How would it even be possible for the timing to be 180 out you can only fit the tool in one hole. I am at my wits end with this thing.

i'm not too sure how the 180 out happens, but from what i've read on this forum, what you describe is pretty much what happens when its 180 out. you'll have to do some searches to see.

did you screw in the service idle screw?

Vincent Waldon · « **Reply #4 on:** September 06, 2007, 10:47:09 pm »

Some questions to generate some possibilities:

Where did you get the replacement IP from ?? Someone you trust, eBay special, junkyard ??

Are you getting a good flow of fuel out of the return line as you crank ??

If you crack the fuel fitting at an injector do you get fuel all the way to the injector ??

Timing was set with the dial gauge as per the Bentley service manual ??

travisdj · « **Reply #5 on:** September 07, 2007, 12:56:47 am »

Quote from: "Vincent Waldon"

Some questions to generate some possibilities:

Where did you get the replacement IP from ?? Someone you trust, eBay special, junkyard ??

Are you getting a good flow of fuel out of the return line as you crank ??

If you crack the fuel fitting at an injector do you get fuel all the way to the injector ??

Timing was set with the dial gauge as per the Bentley service manual ??

Got the pump from Ebay, have been in contact with seller and he is preparing to send me a new pump.

Yes, there is fuel flow in the return line, but also in air in the return line.

Yes, fuel is getting to all the injectors.

Timing was not set with the gauge in mm, but everything else was set per Bentley manual.

In the morning we are going to turn the pump 180 degrees. I am going to get a gauge in mm so that we can have it right on. I really appreciate everyones help. I really don't see how we could have gotten 180 out. I know I sound like an idiot. Thanks though.

Vincent Waldon · « **Reply #6 on:** September 07, 2007, 01:25:55 am »

Nah, you're not an idiot... no stupid questions here !!

If the timing is out of wack (easy to do if you are not using the dial gauge) then it will behave really poorly.

Someone else can chime in on the 180 part... I can't think offhand how this would be possible during your installation (easy enough when rebuilding it however... which is why I asked where you got the pump from).

It could also be that the throttle lever is installed wrong.... again easy to do if you miss a step while rebuilding. Speaking of which... did your pump come with the throttle lever on already, or did you do a swap ?

My guess.... the timing is completely wack *or* you got a bum pump... given that it won't run at all I'd further guess the latter... !!!

travisdj · « **Reply #7 on:** September 07, 2007, 01:37:20 am »

Came with the lever on, but we had to replace the seal due to it leaking. We took it off today to make sure it was on right, and it is now. Still no dice. We are going to turn it 180 in the morning and try that. The pump apparently came off a running car. I just don't get why it revs when the throttle lever is pushed in the opposite direction that it is supposed to move. I love the car, just haven't been able to drive it for 11 months or so.

jimfoo · « **Reply #8 on:** September 07, 2007, 10:10:29 am »

Quote from: "travisdj"

I just don't get why it revs when the throttle lever is pushed in the opposite direction that it is supposed to move. I love the car, just haven't been able to drive it for 11 months or so.

Probably because it was put together wrong.

travisdj · « **Reply #9 on:** September 07, 2007, 10:26:19 am »

Quote from: "jimfoo"

Quote from: "travisdj"
I just don't get why it revs when the throttle lever is pushed in the opposite direction that it is supposed to move. I love the car, just haven't been able to drive it for 11 months or so.

Probably because it was put together wrong.

I would say there is a possibility of that, but it was taken apart yesterday and verified that it was together correctly.

Vincent Waldon · « **Reply #10 on:** September 07, 2007, 11:55:34 am »

I guess our point is that the throttle lever can align with the splines on the throttle shaft in at least 20 positions... so unless it is carefully marked during disassembly it's nearly impossible to get it on correctly without some trial and error.... usually *a lot* of trial and error.

In particular, if you get it on over-center it would be theoretically possible for the lever's action to be reversed.... again, just another possibility.

Vince

travisdj · « **Reply #11 on:** September 07, 2007, 11:58:52 am »

Quote from: "Vincent Waldon"

I guess our point is that the throttle lever can align with the splines on the throttle shaft in at least 20 positions... so unless it is carefully marked during disassembly it's nearly impossible to get it on correctly without some trial and error.... usually *a lot* of trial and error.

In particular, if you get it on over-center it would be theoretically possible for the lever's action to be reversed.... again, just another possibility.

Vince

I hear ya. We left the lever off and tried cranking the car and getting the throttle shaft to work properly before reinstalling the lever, but that was to no avail.

travisdj · « **Reply #12 on:** September 07, 2007, 02:54:30 pm »

Well, I believe you guys were right about the fuel lever. We put it on right, but in attempts to make sure it was closed all the way it got flipped around. It has been corrected and now we are just trying to get it to start. I will keep you updated, so that you may laugh at me. lol

travisdj · « **Reply #13 on:** September 08, 2007, 05:23:28 pm »

Still no dice. Got everything the way it should be, minus using a timing gauge, yet. Changed the fuel filter and it won't even try to start now. I dunno what's going on. I am getting a gauge, so we'll see if that helps.

zukgod1 · « **Reply #14 on:** September 10, 2007, 10:20:54 am »

I hate problems like this.
Are you still getting th IP replaced from the seller?

Hop eyou get it going, getting close to getting mine going as well, been sitting for 13 months now

dan