Author Topic: 1.6TD injection pump ill-running?  (Read 4766 times)

July 13, 2005, 11:45:47 pm

josh arnold

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1.6TD injection pump ill-running?
« on: July 13, 2005, 11:45:47 pm »
I'am having running conditions with my 1.6TD.  I have just recently rebuilt it with all new brgs., seals, .040" KS pistons, wrist pin bushings, 36mm oil pump, had the valve seats bored .040", collin at TT port and polish the head, using a hydraulic head, 1.9 NA camshaft that spec. out larger, Full 2 1/4" stainless down pipe with 2 1/4" TT Flowmaster system,  basically threw all the best parts at it I could.  
I aquired the core from a wrecking yard cheap, taking there word that it was a good running engine, but found that the bores and the valve guides were wasted. I never ran the engine personally untill a week ago. Struggled with it starting for the first time, but finally managed, it seems that the injection pump has strange problems.  
I have the timing set at 1.00.
Anyways, off idle it spits and sputters grey smoke for about 1/8 of its travle untill it gets half way, then clears up.  Now driving it, it drives nice unless you floor it.  It then pull strong until a certin RPM then falls on its face.  Seems like its in the last 1/8th of full throttle that it cuts out, boost seems good, so I'am not sure, maybe I need a Giles special?
I put a can of lubro moly diesel purge in it and the off idle sputter disappeared but its still cutting out at a specific RPM.  You can tell tht it has plenty of more steam in it but, is cut short. Can anyone offer advice?

Reply #1July 14, 2005, 12:29:24 pm

fspGTD

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1.6TD injection pump ill-running?
« Reply #1 on: July 14, 2005, 12:29:24 pm »
Regarding rough running problems, might want to have your injectors checked for proper spray pattern.  Also, compression test to make sure everything is sealing up evenly across all cylinders might not be a bad idea.

If the engine smokes at all, does this smoking go away when the motor "falls flat on it's face"?  If so, it is almost certainly the factory governor mechanism working as it was designed, which is to pull away fueling beginning at around 4100 rpm or so.
Jake Russell
'81 VW Rabbit GTD Autocrosser 1.6lTD, SCCA FSP Class
Dieselicious Turbocharger Upgrade/Rebuild Kits

Reply #2July 17, 2005, 11:27:22 pm

josh arnold

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1.6TD injection pump ill-running?
« Reply #2 on: July 17, 2005, 11:27:22 pm »
The injectors are new, all 150bar and have a beautiful crisp spray pattern.  Finally hooked up a boost guage though, and found that when it falls on its face the fuel doesnt start to tapper off, the turbo makes 12lbs of boost and then immediatly jumps down to 9-10lbs and it feels like you put on the brakes.  Eventually going to add some sort of bleeder valve to adjust pressure to the wastgate, cant imagine the car with a steady 12lbs of boost or more.  Its already a rocket ship.

Reply #3July 19, 2005, 11:07:58 pm

fatmobile

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falls on it's face
« Reply #3 on: July 19, 2005, 11:07:58 pm »
When I lose power in the upper/midrange, I suspect cam timing.
Tornado red, '91 Golf 4 door, with M-TDI 12mm pump, south bend clutch, VNT-15 turbo, 02A trany
MK4s: 2000 TDI jetta, 2003 TDI wagon, 2000 golf 2.0 gasser.
'84 Rabbit with 1.7TD KY block pistons bored to 80mm, VNT-15
'84 GTI with stock 1.6TD starion intercooler.