starting problems

[Zulfiqar]

Hi

I was rebuilding a 1.6 NA motor - and then had a little incident in which I couldnt complete it myself, my friend called in a mechanic fitter to assemble the engine - it seems that he has assembled it correctly with the timing ok and all - but when we try to start it - unburnt diesel is pumping out of the blow pipe on the valve cover - any ideas on what this could be - first it was trying to catch but now the engine is too heavy to turn over - let alone start..

the motor has new rings - new valves, guides, and everything - never had a prob like this after a rebuild

[Golf/Jetta]

heavy to turn over... by hand or starter?

[Zulfiqar]

by starter and hand both

what is puzzling is that the blowby smells of unburnt diesel - and Im getting no smoke at the tailpipe - just puffs of air pressure

[arb]

How are you turning it over by hand ? With a socket and rench on the crank pulley ? How many ft-lb does it take? Until you get all the injectors primed, its not going to want to run and you'll get unburned fuel. Very strange its in the valve cover.

[Zulfiqar]

by heavy you can say its normal for a tight diesel - like you are trying to spin a good diesel with a 19mm combination wrench on the crank pulley.

Ive retarded the pump timing a bit as it was not put on by a dial gauge, its not puffing out now - just heavy on the starter - my gauge got nicked when I gave it to a machinist for making a copy of my adapter..

[arb]

by heavy you can say its normal for a tight diesel - like you are trying to spin a good diesel with a 19mm combination wrench on the crank pulley.

Ive retarded the pump timing a bit as it was not put on by a dial gauge, its not puffing out now - just heavy on the starter - my gauge got nicked when I gave it to a machinist for making a copy of my adapter..

I hope its not the same machinist who put your engine together for you ;-)

[Zulfiqar]

that machinist has closed business for reasons I dont know - I made myself another adapter from the little bench lathe I have.

Anyway - I retarded the pump timing about 1 pencil line - and it does start now after towing, it gives no smoke at all no black, no white, no nothing, the blow pipe is chuffing out light pulses of air - BUT its running on only 3 cylinders the 4th injection nozzle is not working...

  I cant work on it at the moment and Im starting to hate it

[Golf/Jetta]

i wonder if the cam and crank where over tightend

[Zulfiqar]

a little better development - the 4th nozzle was not working proper - serviced it and is spraying nice now, all that comes to mind now is to remove cam and take out lifters - empty them and install them back - because its not able to idle properly

[rabbitman]

Could the little return line off the fourth injector be plugged into the vacuum pump? I've heard of it being done, check the oil.