1.9TD Cutting out - FUEL ISSUE?? = PLEASE HELP

[Tomson]

Hi All,

I am nearly there with my engine conversion.

Basic history -

I bought a 1.9TD from vwcaddy.com with GTD (pump, injectors) parts and a downpipe. I got the GTD pump modified with the gov mod and boost pin. I then found it to be seized, so had the pump rebuilt. The engine was then installed only to find the the head was out by a 4000th and needed a re-skim and that the turbo was shagged.

So I had the head skimmed and the bought another turbo.

This has all taken about 3 months. A local gargae are doing it as their hospital job for a reduced hourly rate.

Anyway it is going for a test tomorrow, which I hope it to pass.

The problem is that although it gets going really well it then cuts out at 3500rpm. Its like it hits a redline and dies 1000rpm short of the actual redline.

I had the gov mod and boost pin done before the pump was rebuilt but asked cheltenham diesel to leave the gov side of the pump and the pin well alone, so they should be in the same settings as they were set to when modified.

Also the 2.%" stainless downpipe is currently mounted to the old exhaust through a reducer untill I have a new one made.

Does anyone have any ideas, my mechanic is about to give up.


Many Thanks,

Tom

[burnt_servo]

put a lift pump in that puts roughly 15 psi of pressure into the injection pump .  for me this made a huge difference in high rpm fueling   for my car .  power went way up along with boost   .

 if your having fueling issues that should fix things .

 asuming you don't have a blocked fuel filter .....  does your car have a filter on the pickup in the tank ?

[Tomson]

Thanks burnt_servo, what is a lift pump? and where would I get one from? 

Also the fuel system is standard 1.6dmk1 vw caddy so no idea on the filer in the tank - I will ask my mechanic.

Drove the caddy yesterday and two things that really bothered me.

Firstly on tickover it really really shakes the whole van about, much much worse than it ever did before the engine upgrade.

Secondly is the dying at 3000-3200rpm, it really is like itis hitting a redline. Not sure it is the pump as it came straight from the guy who modified it and then to cheltenham diesels for the rebuild. I made sure that the chap there did not **** with any of the settings sorted during gov mod.

Also the caddy does not feel anywhere near where I expected 120bhp-ish to be, it feels more like 90 brake.

Forgive me for being a mechanical novice (i think that is fairly obvious by the amount of money spent so far!)

Where should the timing be, any info I can give the mechanic on suggested settings for my spec?

Again my spec is

AAZ 1.9TD
Larger K24 Turbo
GTD Pump (modifed by reg, completely rebuilt by cheltenham diesel)
GTD Injectors
Large FMIC
Skimmed head, so mechanically the engine is sound
2.5" stainless downpipe

Any ideas or settings/timings to try always welcomed. To say I was disapointtd is an understatement.

Also the wing has been dented by another customer at the garage.

I will get it sorted though.

[Smokey Eddy]

Ooooooo a lift pump actually helps? im having high rpm fueling issues. I have the fueling set as high as it will go and i still get decently clear exhaust on WOT.

[burnt_servo]

Ooooooo a lift pump actually helps? im having high rpm fueling issues. I have the fueling set as high as it will go and i still get decently clear exhaust on WOT.

put around 15 psi of fuel pressure into your injection pump and you will be surpised how much power you gain at high rpm's .
the hp gains feel more impressive if you have fiddled with your govenor and can pull over 5000 rpm before the engine defuels .

[Smokey Eddy]

I have my Gov. solid shimmed so the rpm flies as high as the pump will fuel it. I don't know what the limit is which could possibly be dangerous? i removed the spring that gradually limits the fuelling so it should just go straight to the red line and then stop.

Sweet, guess i'll start looking for a lift pump.