83 GTD 5spd "CY" 1.6TD Cold Start issues need help

[fighting_First]

Hello,

About 8-9 months ago I purchased an original 83 GTD 4dr and the car looked nice and ran decent. Since then I have uncovered its flaws with the exception of one thing that is keeping the car from being a Daily Driver.

The engine died about 2 months ago and since then the engine has been freshed. The original problem was thought to be the crank pulley which came loose and killed my C/head. So the engine came out, head removed and professionally rebuilt, valves lashed. The block was not taken apart and looked ok, the original compression check was fair , the crankrod bearings looked clean no problems, although the rings were not check. This was not the first rebuild so we ran with the existing internals, with the addition of new end seals.

Turned out the problem was not from the Crank pulley but from a past accident that damaged the passenger side engine mount and tweeked the diesel pump off a few MM. All of the pulleys have been repaired or replaced, the diesel pump was rebuilt and the car is now operational. Before the engine problems the car was a smoker but ran strong, we found the pump had a "governor mod" we also found incorrect injectors 130bar from a NA 1.6, so the correct Bosch 1.6TD injectors (230bar) were installed.

Only catch is the car doesnt start when its cold, 40 cranks or more with the cold start pulled. Once its warmed up the engine runs good.

The Dpump firm is working on the car right now and having trouble any suggestions?

Thanks, Sean

[Doug]

You sound knowledgeable but have you checked the glow bus for current draw of somewhere around 50-60 amps. Use a series ammeter or a clip on ammeter to check the current. Anything less means a defective glow plug(s). If it is zero then suspect the inline fusible link or the relay. With the motor in reconditioned shape I doubt that it is anything mechanical.

[fighting_First]

inspected and tested with a car battery before the rebuild. Im not sure if thats the correct test proceedure but all 4 were bright red.

One thing that comes to mind now that you mention the bus draw is
the copper bus bar connecting all 4 plugs, it was damaged and now repaired to what I thought was perfect. The only thing missing is the insulation and that was on my todo list.

The electrical system in this car needs some TLC, I will check maybe your onto something.

Question, why does the engine finally start after 40 cranks if the GP(s) are bad?
Thanks,Sean

[Doug]

Cranking the engine will cause it to heat internally by the compression of air alone. Sometimes if the compression is high enough and outside air temperature is not too cold you will be able to start the motor after a lot of cranking. Check your glow bus current draw as I mentioned before. Never check glow plugs by applying a voltage to them while in free air. They can be easily burned out that way. Just use a multimeter set to low resistance to check the internal resistance.

[fighting_First]

the relay located, under the dash?

[jtanguay]

130bar from a NA 1.6, so the correct Bosch 1.6TD injectors (230bar) were installed.

uh... 230 bar sounds more like TDI injector specs... TD is only 155bar as opposed to the N/A 130 bar.  i doubt that is your problem, but worth looking into if you had the injectors pop tested to 230 bar...

could be a worn out pump too.  glow plugs are definitely a possibility, but chances are if they all glow, they are fine.  doesn't mean that the electrical system controlling them is fine though...  how did you test them with the car battery? while in the head and hooked up to the stock glow system or with a direct connection from the battery?

[fighting_First]

of my head, but I swear somewhere on the injector it said 230 all of them are new bosch and Im 99.9% positive they are the correct 155 set.

The pump was shot and then rebuilt 2 days ago and is said to be working fine. The glowplugs were tested in a crude manor outside of the c/h and the entire electrical system needs some attention, tomorrow I will have a look see.

The car sat for 2 months and like every car I own when it sits problems start.

My gut is the electrical system needs TLC, after the rebuild I noticed the wipers are only working on slow speed, rear wiper doesnt shut off, reverse lights are always on and the engine doesnt start unless its cranked 40x.


Thanks again,
Sean

[jtanguay]

if you want to determine whether or not its the glow plugs, just disconnect the bus bar and connect it directly to the positive on the battery.  just be careful as a lot of current flows through it and u could injure yourself or cause a short, resulting in exploding battery with acid going everywhere.

leave it connected for about 15 seconds, and then disconnect and start the car.   if she starts then you know for sure its the glow plug electrical system.  if not, its most likely a few bad gps or even some other problem like fuel related???