Poor starting on Franken Engine

[barrygti]

1.) check glow plugs
2.) check glow plugs
3.) advance it some more
4.) advance it some more, till you dont like how much it rattles.
5.) check your timing mark on the flywheel. i had a timing gremlin for the longest time, and it turned out to be my flywheel causing me to not be able to time it right.
6.) check your battery cable connections at both ends, at the battery, and on the starter and body. make sure they are spotless clean. even grease them if it makes you feel better. grease prevents corrosion.
7.) check that your pump hasnt skipped a tooth on the sprocket.

being a franken built engine, you probably cant really use a timing spec from a certain engine. you will probably have to play with it till you get it the way you want it. thats part of the territory when you start building something out of pieces that were never designed to work together.

1. They are 100% good
2. See above 
3. Done that
4. Done again until it was tooooo noisy, still wasn't easier to start though.
5. Good though, I am using a Skoda flywheel/clutch assembly but it was in line with TDC when I had head off I am sure. I also marked the bottom pully at TDC so I use that also.
6. Done a voltage drop test on battery cable and was perfect.
7. Pump lines up perfect, checked timing 4-5 times now and runs GREAT when she is on road.

It's a NIGHTMARE as it's the only slight issue I have, don't get me wrong she always starts eventually, just a bit embarassing.

[theman53]

what kind of compression #s do you have? It would seem if everything else is ok then you should do a compression check and while you have it out try the 1.6 injectors.

[Rabbit on Roids]

oh wow, totally missed that you have AAZ infectors. i bet anything that is your problem right there. im pretty sure dual stage injectors were designed to work with dual stage pumps only. and standard injectors will work with a dual stage pump, but im pretty sure they arent backwards compatible. i remember reading somewhere that you cant use double pop AAZ injectors with a single pop 1.6 pump because of the cam plate being too aggressive for the injectors or something. i dont think they really allow you to time it that accurately.