Author Topic: Crazy basterdised build first start issues, may be pump related???  (Read 6759 times)

Reply #15February 05, 2010, 09:56:06 am

Rabbit on Roids

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Re: Crazy basterdised build first start issues, may be pump related???
« Reply #15 on: February 05, 2010, 09:56:06 am »
i've taken the pump to a bosch specialist to be rebuilt. will report back next week once it is fitted.

looks like the mk3 weighted rod is way too short and knocks the 'ball' out of alignment! no way would any downpipe fit at the moment!

Rolo, the 1y pump i have has a 8mm head!!! lol

thanks

Ryan

1Y basically has a eco diesel injection pump on it doesnt it?

Reply #16February 05, 2010, 10:35:50 am

rolo

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Re: Crazy basterdised build first start issues, may be pump related???
« Reply #16 on: February 05, 2010, 10:35:50 am »
My "Autodata"  tells me there is a10mm version
the last one

Reply #17February 05, 2010, 11:40:03 am

ryanp

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Re: Crazy basterdised build first start issues, may be pump related???
« Reply #17 on: February 05, 2010, 11:40:03 am »
gear linkage.... shorten the tie rod.

or shorten the arm.

It's normally doable with a standard linkage, if you have a decent downpipe ;)

Reg,

Tried a shorter weighted rod, wont even work with it! shortening the  arm will increase the throw?

I cant see how a downpipe would fit the standard linkage at all, maybe an Up-Pipe would!  lol

rolo, i'll go look at some other 1y's. Need to install my copy of Autodata too!
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Golf Mk2 TDi Van - 250WHP

Reply #18February 06, 2010, 07:11:43 pm

ryanp

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Re: Crazy basterdised build first start issues, may be pump related???
« Reply #18 on: February 06, 2010, 07:11:43 pm »
any help with the linkage? will be fitting the intercooler tomorrow and sending it off to my mate for the end caps welding on!

ry
Brand new TDi injector sets:
http://www.vwdiesel.net/forum/index.php?topic=25862.0

Golf Mk2 TDi Van - 250WHP

Reply #19February 12, 2010, 12:49:59 am

ryanp

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Re: Crazy basterdised build first start issues, may be pump related???
« Reply #19 on: February 12, 2010, 12:49:59 am »
linkage issue resolved! how it was:



with the downpipe on it almost caught in neutral!

made a short shift without the need to weld:



Just warmed it up and bent it to suit, one hole and it's done. reduced throw by about 30-40%.

I made this too to swing the arm out of the way a bit more:



its a mk3 weighted rod made to be 25mm shorter than the stock mk1 item

to be on the safe side i've made a brass bush for the part nearest the DP in case it melts the stock plastic one, as well as a better bush made from nylon for the other end as the new one was sloppy!





This is with the linkage in second gear, it would nearly catch in neutral before!



It fits perfectly! I can now get all 5 gears and love the way the shift feels!!

The rebuilt pump also came back, the guy said it was caked in crud inside from old diesel ect and it was a suprise it did not damage the pump when starting the engine!

I refitted it, timed up to .95 advance this time, and after a minute or two bleeding the HP side it fired right up! tickover needed adjusting down and that was it!

took it for a little drive up and down, its loud! and the poly mounts i fitted are coming off today! i need new fillings in my teeth! I also have a slight oil leak from the sump and the filter housing, will run it for a bit and then swap the sump gasket and re-torque the housing. the oil line is closer to the driveshaft than i would like so if that has any signes of touching after a few miles i'll  mod that to be how i initially planned, the hydro shop gave me the stiffest braided hose known to man so i could not bend it into the block to be p-clipped.

other than that, fit the I/C when it comes back and i'm done!!!! lol i could have chose an easier swap for my first engine conversion!
« Last Edit: February 12, 2010, 10:08:47 am by ryanp »
Brand new TDi injector sets:
http://www.vwdiesel.net/forum/index.php?topic=25862.0

Golf Mk2 TDi Van - 250WHP

Reply #20February 12, 2010, 07:37:03 am

regcheeseman

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Re: Crazy basterdised build first start issues, may be pump related???
« Reply #20 on: February 12, 2010, 07:37:03 am »
Well done mate.  ;D

Reply #21February 12, 2010, 10:01:58 am

ryanp

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Re: Crazy basterdised build first start issues, may be pump related???
« Reply #21 on: February 12, 2010, 10:01:58 am »
Cheers Reg, I've learned a few thing whilst doing this, mainly to swap anything that 'might' need swapping whilst you have the chance.

This brings me onto my next point, what cheap/uprated clutch can i fit to hold with a mildly tuned engine?? the stock one now is slipping like a ***, either due to oil contamination or just wear (most probable as it's right at the top of the pedal!)
Brand new TDi injector sets:
http://www.vwdiesel.net/forum/index.php?topic=25862.0

Golf Mk2 TDi Van - 250WHP

Reply #22February 12, 2010, 10:13:56 am

ryanp

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Re: Crazy basterdised build first start issues, may be pump related???
« Reply #22 on: February 12, 2010, 10:13:56 am »
and i recon the timing needs setting a little more advanced as the cold start lever makes it a little smoother even though it is not that cold!
Brand new TDi injector sets:
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Golf Mk2 TDi Van - 250WHP

Reply #23February 12, 2010, 01:56:50 pm

RabbitJockey

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Re: Crazy basterdised build first start issues, may be pump related???
« Reply #23 on: February 12, 2010, 01:56:50 pm »
whered id you get that flexible intercooler hose?
01 Jetta TDI 100% stock daily
81 Rabbit:TDI-M ported head, Frank06 cam, PD intake, hybrid T3 turbo, Renault intercooler, Syl20 11mm pump, light weight fw, and yellow California Clutch clutch kit

Reply #24February 12, 2010, 02:17:53 pm

truckinwagen

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Re: Crazy basterdised build first start issues, may be pump related???
« Reply #24 on: February 12, 2010, 02:17:53 pm »
looks like pool hose to me.
83 Opel Kadett Diesel

Reply #25February 13, 2010, 12:51:57 am

ryanp

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Re: Crazy basterdised build first start issues, may be pump related???
« Reply #25 on: February 13, 2010, 12:51:57 am »
It's made for automotive use, good to about 1bar aparently. I got it from a local place that sells silicone parts. was £40 for 2m

Ry
Brand new TDi injector sets:
http://www.vwdiesel.net/forum/index.php?topic=25862.0

Golf Mk2 TDi Van - 250WHP

Reply #26February 13, 2010, 04:14:56 am

stewardc

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Re: Crazy basterdised build first start issues, may be pump related???
« Reply #26 on: February 13, 2010, 04:14:56 am »
A GTD pump is built for single stage injectors, while a 1.9 has 2-stage injectors. Get a set of GTD 1.6 injectors for it.

Reply #27February 13, 2010, 11:12:30 am

ryanp

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Re: Crazy basterdised build first start issues, may be pump related???
« Reply #27 on: February 13, 2010, 11:12:30 am »
doubt that makes any difference, i do want to fit GTD injectors and new nozzles though in the future!

need help with the clutch!
Brand new TDi injector sets:
http://www.vwdiesel.net/forum/index.php?topic=25862.0

Golf Mk2 TDi Van - 250WHP

Reply #28February 13, 2010, 12:15:21 pm

theman53

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Reply #29February 13, 2010, 01:20:37 pm

ryanp

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Re: Crazy basterdised build first start issues, may be pump related???
« Reply #29 on: February 13, 2010, 01:20:37 pm »
hoping for something in the UK really or with factory parts, is it an 8v disc and 16v pressure plate what i need?

Thanks!

Ryan
Brand new TDi injector sets:
http://www.vwdiesel.net/forum/index.php?topic=25862.0

Golf Mk2 TDi Van - 250WHP