Author Topic: Non Starter after TD swap (Read 4422 times)

VelocityConservation · « **on:** October 19, 2007, 07:41:47 am »

I have dropped a 92' 1.6TD into my 90' NA shell (Jetta).

I am at the 7 months mark from when I pulled the running TD to now. I replaced or rebuilt everything except I did not take the head off or injectors out. Motor was not original to the donor, and seemed (based on component wear) to have approximately 150k on it.

Now it won't start. It doesn't even "pop". If I crank for 20 seconds wisps of smoke are coming out of the downpipe.

Things I have tried:
1. Primed pump and injector lines. Cracked each line at the injector and cranked until fuel w/no bubbles.
2. Timed the engine multiple times. Setting to .040in (=1.016mm)
3. Took the timing belt off and lined everything back up again and retimed the motor.

Things I think are true:
1. Since I have fuel at the injectors I believe the stop solenoid to be working properly.
2. It is about 75 degrees F here in NC so even if the glow plug system doesn't work (which it is putting power to the buss, but I have not tested each glow plug) it should still start.
3. The Fuel is 7months old.

Next on my list:
1. fresh fuel
2. test all glow plugs
3. Last resort, I have a working NA pump that I will try.

Okay so the questions are:
1. What are the things I think are true which are not necessarily so?
2. What stupid thing am I overlooking? (this is what usually bites me)
3. Is 1.016mm enough static advance considering the that it is a TD and its current condition?
3. What other things should I check or try?

Sorry in advance for the length of the post, but wanted to get as much info as possible out before asking my questions.

VelocityConservation

saurkraut · « **Reply #1 on:** October 19, 2007, 08:12:35 am »

I suspect glow plugs are the issue. Either the plugs are bad, the fuze is blown, or the relay is shot.

Since you have no pop at all, check to make sure there is power to the plugs. It would be a real freek occurance for all the plugs to be shot.

You can go right from the battery to the glow plugs and probably get it to fire. Jumpercables work, or make a jumper cable with aligator clips from the same gauge of wire as the glow plug wire. My '79 is a daily driver, and my custom made glow plug jumper is a good friend when you drive something that old.

blkboostedtruck · « **Reply #2 on:** October 19, 2007, 01:00:15 pm »

pull start! thats what i do to get it started ! that gets the fuel primed up tp the injectors! do it all the time! even with cars that i buy that have been sitting a long time that the P O could not get started! make sure your brakes work!!!
good luck Duane

westcoaster · « **Reply #3 on:** October 19, 2007, 04:18:13 pm »

Hold the gas pedal to the floor when cranking.

When I bought my samurai with the diesel swapped in, timing was out, pump was leaking, and massive blow by. The previous owner couldn't get it started. Jumped the battery with the truck, mashed the go pedal and cranked. It eventually fired....

jtanguay · « **Reply #4 on:** October 19, 2007, 05:05:01 pm »

with an already tired motor, the gp's are essential. without them you could crank for a few minutes with no go, and maybe only a puff here and there, depending on how tired the motor is.

VelocityConservation · « **Reply #5 on:** October 22, 2007, 07:30:08 am »

Thank you for all the replies.

And the answer was, Glow Plugs. Well actually the glowplug system.

The fuse that is under the rain tray had a "tear" in it. So it would still sent voltage but could not carry enough amperage to get the job done.

I grabbed one from my parts car and the motor starts up as soon as you turn the key now.

Now for the next challenge. Idles fine, but seems to starve for fuel at anything over 2000 RPM. I will start with a new fuel filter.

Thanks Again.

VelocityConservation