IP Leak

[vako]

i've got some strange thing going on with my ip pump. when i floor the throttle in gear (for example in 2-nd or 3-rd) at about 4000 rpm, engine stops accelerating and it shakes like crazy, on lower revs it works fine for diesel engine, no excessive vibrations.  yesterday when i moved throttle lever with my hand i saw that at certain rpm-s ip squirts out a little cloud of diesel from the back side, it happens somwhere about 3800-4200 rpm.  but on idle it dosn't shake like it does under the load and i think that revs much higher.    

 ip leaks from this part, marked with red circle



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i do not have tachometer so i count rpm-s according to the gear and speedometer  
teh engine is wapped into suzuki vitara using home made adapter plate , but balanced suzuki flywheel was drilled and fitted to the engine in the workshop, so i dont think that ip and shaking problem is related with the swap.    

and i would also mention taht it dosn't black smoke at all think that fuel screw should be adjusted

[vanbcguy]

The leak is coming from the vent on your LDA, it most likely means that your LDA is full of fuel.  There is a seal inside it that is only accessible after opening up the pump, by which point you need to do the pump cover gasket and throttle lever o-ring too.  By that point you might as well reseal the whole pump since you're most of the way there already!!

Pump internal pressure increases with pump RPM, so if a seal is just starting to go that can explain why it only leaks at high speed.

Also not sure if you have your governor modified or not, but the stock governor would be shutting off fuel right around the point where you are saying your engine stops accelerating. 

[Vincent Waldon]

The FAQ has details on resealing the pump... including a good thread on the LDA specifically.

[vako]

i forgot to mention that it is aaz, 1.9 td from passat.   no my pump is bone stock, i think. because i know noone in georgia who could perform this modification

so 4000-4200 max rpm is normal for my engine?   it stops accelerating as gas engines limit the revs, but engine shakes twice as much (diesels are normally more shaky than gas engines ) before that limit it pulls very well under the boost.    if it should be so than i will leave it alone.  only fuel screw adjustment is planned
 
i did not know that it was a vent plug    when it blows out there is mostly air , and a tiny amount of diesel...      if it is not a big issue and my engine can be run like this for 6-7 K miles then i will reseal it later, because there is no leak from the pump except for that. and after the swap i'm seriously short of money

thank u very much for such a quick reply (Y)

[vako]

Also not sure if you have your governor modified or not, but the stock governor would be shutting off fuel right around the point where you are saying your engine stops accelerating.  

is it normal to feel more vibrations when governor shuts the fuel under the load? it feels like the engine starts to  misfire, i feel high frequency vibrations even on the steering wheel  otherwise engine works fine for me, no misfire even when cold (with cold start lever out) when it warms up it idles perfectly. and it does not shake

[vako]

and sometimes small bubbles appear in return line. is that very seriozus problem, or i can live with that?

 i know i have lot of questions but it's the first week of driving vw diesel suzuki vitara so try to find all the problems and get as much informations as possible.

my goal is 10 000-15 000 kilometers on this engine, that is almost 3 years of driving for me

[vako]

yes i saw that link   i think it will require removing ip, because for newbie it will be veeery complicated doing this kind of job o the car so i think i will postpone this job for summer holidays.


and what about the revs, is my case normal? :?

[vako]

is it normal to feel more vibrations when governor shuts the fuel under the load? it feels like the engine starts to  misfire, i feel high frequency vibrations even on the steering wheel   otherwise engine works fine for me, no misfire even when cold (with cold start lever out) when it warms up it idles perfectly. and it does not shake

is this normal for stock 1.9 td , which came from european wv passat?

[745 turbogreasel]

^Agreed,and if your fuel filter is restricted(old), it will be more inclined to pull air  through a weak hose connection under high load RPM conditions.

[vako]

thanks for info. i will check fuel filter and all the hoses.  and what do you think about rpm . i will also adjust max fuel screw. because there is no smoke at all and engine puuls only after 1500-2000, before that i feel serious lack of power. it fels like my underpowered 1,6 suzuki engine