Help need to lower idle and turn up the POWA some moe. - IDI Engine - VWDiesel.net The IDI, TDI, and mTDI source.

• Help need to lower idle and turn up the POWA some moe. by gorillam on 25 Jan, 2006 20:40
• I've installed my custom massive injector nozzles, done the injection timing a little more advanced, sounds nice, fuel screw up to runaway no wastegate.
  
  Now how can I get more fuel into this engine without having this stupid run-away idle if I turn up the Powa screw any more :>
  
  I also have a pretty open exhaust.
  
  Do any of your engines get this "running rich bogging" type feeling like my 2 stroke dirtbike, it just feels to bog a lot with this much fuel.
  
  Also anyone in calgary experienced with rebuilding engines that wouldnt mind helping me slap some new pistons+rings in my engine some weekend. I am mechanically inclined, I am just scared of messing up stuff and would appreciate someone that has done it before to supervise.
  
  yes I have egt gauge and boost, however the VDO gauge sucks ass, it responds so slowly, I want my $210 bucks back from concept1...
• #1 by gorillam on 25 Jan, 2006 20:42
• Forgot to menation, 1986.5 TD HYD head.
  
  396,000kms stock engine, with a funny grinding noise that is getting progressivly worse with high rpm boosting.
• #2 by malone on 25 Jan, 2006 22:34
• Quote from: "gorillam"

  I've installed my custom massive injector nozzles, done the injection timing a little more advanced, sounds nice, fuel screw up to runaway no wastegate.
  
  Now how can I get more fuel into this engine without having this stupid run-away idle if I turn up the Powa screw any more :>

  
  
  Can you tell me more about your custom nozzles and where you got them from?
  
  As for more fueling, have you considered or checked the following (all these are searchable):
  
  1) Ensure that the boost pin on the pump is aggressive as possible. The deeper the taper is (facing towards the pump's pulley), the better. You can grind down the taper a little more with a dremel. This may not increase your max. fueling but try adjusting the wheel ("starwheel" or "gear") below the boost pin to adjust how quickly fuel comes on. It's good to be aware of this feature. It may even reduce your bogging issue if you're getting too much fuel under minimal boost, thanks to the big flowing nozzles.
  
  2) Governor modding. Improves fueling above 2,800 RPM to 6,000 RPM or wherever your effective powerband ends.
  
  3) Upgrading the pump's head from 9mm to 10-12mm. I wouldn't go too big if you plan on revving higher than 4,500 (12mm) or 5,000-5,500 (11mm?). Maybe you are bogging because the fuel is flowing through your nozzles too easily without atomising properly. The larger displacement pump head will increase injection pressure and therefore improve fuel atomisation.
  
  4) Higher lift camplate from 1.9TD pump. Like mine, your RPM may be limited to just above 5,000 RPM with this camplate.
  
  ... and I probably forgot something else.
  
  #1-4 above range from easiest to hardest, respectively. Don't underestimate the boost pin's capability. The stock 1.6TD pin may look nice but it definitely can be upgraded. The stock pin's hourglass form is limited whereas a straight cylinder with a big notch is most aggressive (this is what I have).
  
  Has your injectors been pop-tested with the new nozzles installed? If so, how was the spray? Is the breaking pressure still ~155bar?
  
  If you don't know what the heck I'm talking about regarding anything above, feel free to ask.
  
  

  Quote

  yes I have egt gauge and boost, however the VDO gauge sucks ass, it responds so slowly, I want my $210 bucks back from concept1...

  
  
  You're not the first person to find that a VDO EGT gauge is slow-responding. Try asking fspGTD on this site about thermocouple options. He has a VDO gauge too and it's supposedly faster responding with a different brand/type of thermocouple.
• #3 by gorillam on 26 Jan, 2006 10:06
• Thanks for the reply Malone lots of info I needed,
  
  My nozzles were GTD nozzles from kermaTDI that I had my cousin (a machine'ist for my dad) further machine them out I dont quite know how much material he took off. I have not actually hooked it up to a bench or a pop test to see the spray pattern or to test what pressure they are crackign at. After what you said I do belive that the bogging is due to crappy injector cracking and probbaly a little bit of a spray pattern issue. I have not pop tested the injectors, I also did notice the intermediate plate in the injectors was scratched to h*ll. I know after installation I had a big problem with them not cracking fully. This went away after a bit of time, and some more injection timing, somehow that cured it a lot.
  
  I will try the following mods progressivly and slowly and see if I can get some more fuel into this baby.
  
  Also, where can I get a good priced pop tester? And how much do the used ones typically run for.
  
  
  Thanks a lot. I'll keep you updated, and maybe some pics.
• #4 by gorillam on 26 Jan, 2006 11:24
• I've been bagging on the car with the nozzles for about 10,000 km's. Been back to bc twice up the big hills, egt's are low.
  
  I dont think it's that messed up, it probably just needs some re-shimming of the injectors?
  
  I guess I should have tested them first, however anyone have a pop tester in calgary?? or know where you can get one super super cheap.
  
  I've got a TOIGHT budget on the car.
• #5 by BlackTieTD on 26 Jan, 2006 11:31
• build you own. run a search on this forum.
• #6 by gorillam on 26 Jan, 2006 12:19
• Sweet thanks man.
• #7 by malone on 26 Jan, 2006 12:47
• Quote from: "gorillam"

  Sweet thanks man.

  
  
  If this is your first time pop testing an injector, I suggest grabbing a few stock injectors so you can compare the spray against your customised nozzles.