rough running since the copper washers were changed.

[golden01]

Hello.  I have a restrored 1981 VW caddy.  I put a 1.9 NA engine in it and it has run quite smoothly for 10k miles.  I believe the IP is from a 1.6 NA

Developed a leak and diagnosed the need to replace the washers.  I had my mechanic do this, then the leaks stopped, but rough running, like it is missing on cylnder occurs.  since then, we have replaced all four injectors, and all four lines.  No leaks, no air in the lines.  Replaced the fuel filter.  Still, It runs rough.  Disconnecting each line individually to the injector seems to give it an equal loss of power--thus it seems to be a problem at the pump.  I can drive it at 70-75 mph--smooths out some, but misses when going up a hill.  Pulling the cold weather start out seems to improve it, but it is still missing a smidge when going up hill.

I have bought a timing kit so my mechanic can check the timing.  If this does not work, then a new injector pump will be next as I do not have the time or garage(newly divorced) to piddle with IP.

Is there something simple I am missing?  Marble sounds when it starts with recent cold weather.  My mechanic does not recall diesels running rough like this after simply changing the copper washers in the pump.

At least it no longer leaks!

Take care.

Golden 01

[arb]

The copper washers you had replaced are the seals on the banjo bolts for the fuel supply / return on the IP ? You are sure he replaced both washers on the IP supply line ? One goes above the fitting and the other below.

Is the exhaust smokey ?

[golden01]

On the fuel supply.  the leaking was the two lines closes to the ground at the injection pump.  The vehicle smokes some when accelerating.

What I saw on the drawing of the pump was four copper washers that compress fit to the four injector lines at the pump.

Thanks.

golden01

[arb]

I think you might have several things happening here.

First, the missing was probably from air in the supply line when the washers were replaced. If he didn't correctly install the correct washer above and below the fitting, you'll still have some air in the fuel and still will have missing.

Second, were the injectors tested ? They could be out of adjustment or not working correctly.

[golden01]

There is only one copper washer per line.

golden01

[zukgod1]

There is only one copper washer per line.

golden01

On the injector lines yes but on the inlet and outlet there are 2 pr line as ARB has mentioned.

One under the line and one on top so the lines are sandwiched between the washers.

[golden01]

We did not mess with the inlet or outlet as it was not leaking there.

Replacing the copper washers solved the leaking.

golden01

[golden01]

When I transferred the engine to the caddy, I made sure the inlet and outlet washers were in place.  These were not disconnected.  i can double check to make sure the lines are tight, but again, no air bubbles in the new clear fuel line from the filter to the pump.

golden01

[golden01]

just talked with Danny my mechanic.  He did recheck the washer set up(he coached me through doing the engine and tranny transfer--worked with me for 6 years on my TDI's)  and felt the set up as described was functioning.

he will order a new set of copper washers(less than ten dollars) and will install them.  Maybe a washer is bent oddly...

the new injectors and new lines did not improve the performance, but make it look nicer!  

If this does not work, we will get a rebuilt pump from a certified bosch dealer like the fellow who answered my question!!!

thanks a bunch.

golden 01

[arb]

You probably would be happier if you sent your pump to Giles in Ontario. The certified Bosch dealer might even cost more than Giles and it will not be as good as what Giles can do to your pump.

http://www.performancediesel.ca/index.htm

Phone: 905-940-2266
Fax: 905-940-2261
E-mail: [email protected]

[golden01]

my mechanic and I decided to go ahead and take a second look at the delivery valves after he placed the washers...

At injector pump delivery valve number 4, the SPRING was broken!!!

He fashioned one in the shop for me as I had to drive 170 miles up to Carmel Indiana.  Truck is running like a charm, no hesitation!!!

We will consider putting in the 4dollar US spring in, but if it aint broke do not fix it.

He has worked on diesels for 27 years(Danny Vories, Import Auto-Vincennes Indiana) and never saw a delivery valve spring break.

I have my Porche/diesel rabbit pick up back!  It is loud, but it really hauls butt downt the freeway.

Have a great day.  I appreciate all the help given to me here.

golden o1

[zukgod1]

Awesome! Glad you got it figured out.

[burn_your_money]

It is very rare for delivery valve springs to break but it does happen. Glad that you got it figured out

[golden01]

:oops:    :lol:

I am very glad as well!

Have a great weekend.

golden01