1.9TD Coupe Project

[zagarus]

The good part is that putting it all back together will only take me a weekend. The bad part is I won't be able to drive it home for a bit because of the Coquihalla Highway.  I'm not chancing any rock chips.  It will probably have to stay in Kamloops until end of March, mid April.  No rush though Need to break in the engine anyway before going on a 4 hr highway cruise.

[CrazyAndy]

So are you still considering selling your AWIC setup?  Could you PM me if so?

Either way, this is a beautiful example of a MK2, and shell definitely be a sooty show-stopper wherever you go.

I know how it is waiting a number of YEARS for an engine build.

[zagarus]

Thanks for the kind words, I'll give the AWIC another chance, I just need to revamp it still and make a resevoir for it, should make it easier to deal with.  I do have the small exchange unit. I just have to retap one of the inlets and it's good to go.  It's the smaller non painted core if you go back through my pictures. I could sell that one cheap if you'd like, You'd have to take care of the rest though (ie heat exchanger, hoses, pump, etc)

Will be updating thread as I make progress

[zagarus]

Completely forgot about this. This was before the engine came out for a second time due to broken pressure plate (you can hear it scraping at the beginning before I release the clutch).

http://www.youtube.com/watch?v=8Z_HE2kl-uY&list=UUmsXQRzePA7jE8-I2YVkprg&index=2

[zagarus]

Started work on the rebuild yesterday, started with this this morning:




Finished the day with this:



Tomorrow I'll hook everything up and make sure I didn't miss anything and finally start it up!!

What would everyone recommend I run for timing? 

[CrazyAndy]

I actually have seen that video before on youtube before now.  NOW I remember this car better!

Great to see it finally back together again.  Don't really have recommendations for pump timing, though; haven't done it yet.

[8v-of-fury]

Looks like from the pictures you are using a full 1.9 pump.. They suggest a factory setting of 0.80 +/- 0.02 mm, but that is a little low for real life lol.

I have my AAZ timed up above .95mm I am sure.

[zagarus]

Well she sort of lives as of today!

The car fires up after waiting for the glow plugs, seems to idle properly for a few seconds then it slowly gets more and more rough before dying.  There is no throttle response from the pump. I can't see it being a timing issue as im pretty sure I did everything correctly (will double check tomorrow again). Other possible theories include, 2 year old diesel in tank, fuel pump sitting on shelf for almost two years (maybe a little gunked up inside).  Other then that everything else engine wise is brand new. 

I'm going to check my timing once more and possible run some diesel purge through the pump.  AT this point I'm a little bummed out it didnt come to life more smoothly but on the bright side it saw it's first glimpse of life in a long time

[zagarus]

Here's what it did. Anyone have any ideas? *CLICK PICTURE FOR VIDEO*

[745 turbogreasel]

Smells like air getting the fuel ,or unable to escape to me, not that some slippy stuff won't help everything.

[8v-of-fury]

Starting, no throttle and then stalling is pretty much text-book air in the fuel pump. If it cannot pull more fuel in to replace what you have burned, it stalls. It cannot rev up if there is only enough available to idle the pump either.

You more than likely have a fuel line leak, letting air in.

[CrazyAndy]

Did you use new washers for your fuel line banjos on your pump?  Did you try taking off your fuel tank cap to see if it could pull fuel then? New fuel filter/hoses/lines?

Lift pump?

[theman53]

I think air as well, but how long has the pump sat? Could be a little stick in the vanes?

[zagarus]

it sat for almost two years :\  My guess is also on the pump being gunked up a bit. Think I might send it and the injectors to Giles to take a look at for me.  Sound like a good idea or is there something I can do?

[theman53]

Leave it sit with ATF or diesel purge in it for a few days.