mTDI no fuel

[fourstar]

Hi.

We build an mTDI(AHF) engine pump base from 1.6TD(JR) plunger, cameplate and head(10mm) from TDI(AHF). Engine works fine except when turbo kicks in there is no acceleration, no smoke at all. Engine works like well modded SDI   We tried to adjust more advanced injection timing, turned starwheel down, max fuel screw turned in, but with no success. Turbo boost is stable 10psi.

Does anyone knows how to increase fuel delivery or whats wrong with a pump?

Any thoughts would be appreciated!

I am beginner at mTDI's.

[famous phil]

Hi , by the sounds of things from what you've assembled something may not quite measure up , did you check the rotary plunger lift measurements with a dial gauge  ,the later pump I have is about 3.09mm lift

[fourstar]

No, i didn't. How to do that? like measuring timing advance?? And correct lift must be like you have 3.09mm???

[famous phil]

  Hi , yes dial test indicator or digital vernier should read about 3.09mm , a  couple of my MTDi  pumps  = 190bar another pump = 220/300bar these seem to have the same measurement , what was the tick-over like when the pump was first fitted ? how did you adjust it ?

Regards Phil

[fourstar]

Hi again!

By tick-over you mean how smoothly the engine run at first time?
Here is the engine first run video, timing was way to retarded:
m-TDI first run.
Another issue is cant get low-normal idle, weather it is to high or is normal for a moment and then drops to too low. Min throttle screw is turned out and idle we adjusted by max fuel screw.

[rubadubdub]

Probably the only clip in the world of a diesel engine being started to the sound of Four Non-Blondes

[fourstar]

@rubadubdub  If you mean it by the music it was background playing radio, just coincident.

We measured the plunger lift, could it be possible that lift is 4.2mm? We measured without dial indicator.

BTW I forgot to mention that starting form cam plate to head all parts(Cam plate, spacers/shims, plunger, plunger springs and head) are from TDI pump, but shaft, roller ring and fuel supply pump is from 1.6 IP! I remember TDI plunger springs were bigger and stiffer than IDI 1.6 IP springs.

[famous phil]

 :)Hi , is your boost gauge T'd into the pressure pipe to the aneroid ?
           I've built a few of these pumps and sure none that I've found as yet have a lift of 4.2? I'll check the ones that come in today , early 190bar and later 220/300bar the higher pressure one has a much more aggressive camplate ,but still think this is 3.09lift  ,
I have the use of machinery like the one below just to make sure everything measures up to factory tolerances

 

my pal has had this engine sitting for 12 years not been able to get it running , I wanted to check his pump worked OK , so removed some internal crap and replaced with some of my parts , turns out the pump is OK   I've now fitted the pump I built  and alls going well  -don't seem to have any sound

 
 

[fourstar]

Yes boost gauge is connected into the pressure pipe to the aneroid and at the beginning we tested engine without boost gauge attached.