Try to start Frankenmotor for the first time.....

[regcheeseman]

GTD block, AAZ pump and injectors, TDI 10mm head all timed at 1.1mm

Hung a small motorbike expansion tank from the roof filled with diesel, and a line down to the pump inlet, open the inline tap and the pump swallows the tank contents (600ml)
Another top up and time to crank,

crank

crank

crank

crank

flat battery.  

roll up the other car and attach the BIG jump leads.

crank

crank

crank

crank

nothing, fuel doesn't appear to be dropping in the tank,  

then I spot a dribble of diesel on no2 injector union and tighten it

crank, crank

number 3 joins in and number 1 and they get tightened.

crank, crank and now there is a spurt of what I presume is diesel coming up from low down on the pump, A quick look reveals that it's engine oil squirting from a pipe on the filter top that has not been tightened properly

crank crank and number four starts to spurt  

ign off, ign on ....full glow

crank...wump, wump, clack, wump, wump, wump, clack, clack,wump, wump, wump, wump, wump, wump, wump, wump, wump, wump,

I repeat the process a few times and every time the number of clacks increases

then it fires, runs and dies - no fuel left in the header tank.

I top the tank and try again..... a few cranks and it fires and idles, hunts around a bit then settles - I try to rev it but it won't

I'm now conscious of two things.... I still have a rad pipe to fit and fill engine with coolant so I can't run it for long, and that I can no longer see the back of the garage  

I make my escape and go get a camera


Ok it'll need some tweaking, but for now I'm happy it runs.

[Alcaid]

Great news! Is the vnt up controller up and running as well?

[regcheeseman]

Is the vnt up controller up and running as well?

nope, not quite.

(And less of the 'c' word)

[theman53]

great news. Good luck and make me that controller please sir lol

[wdkingery]

Congrats!
Why did you do a Franken motor?

[regcheeseman]

because the 1.6 engine was free, the 1.9 head was free, the pumps were nearly free - so why not!

I built it because I was running a 1.9 in my daily and having run GTDs previously, I loved the way the 1.6 spun up and it's driving fun. So I wanted the 1.6 bottom end, apparently the 1.9 head has better porting  and could make more power.

But mainly I built it for the challenge.

[Mark(The Miser)UK]

Good to see your 'invention' gradually changing from theory to practice.

Meanwhile will you manage another first and become the first dieselhead to die from carbon monoxide poisoning?

[regcheeseman]

I was playing with the timing last night, had to evacuate several times!

I've got it to idle but it will only just rev a bit, a few hundred rpm with full throttle

I've got the timing advanced on the pulley slots as far as possible (1.2 mm preload)

I tried winding the fuel screw, it went all the way in to the stop without much change in revs.

Fuel supply is good, but lifter vanes may be stuck as it does seem to lift fuel as rapidly as other pumps I've seen sup a quart of diesel in a few seconds (these pumps may have had a lot of air in though)

What do you reckon?

I was thinking of jumping the pulley a tooth on the belt to allow more adjustment on the slots, and more advance. Any hint of retarding the timing and its black smoke/hunting/cutting out.

[ORCoaster]

Sometimes to much advance it just as bad as to little.  Have you tried to start it at full retard in its current configuration?  Just an idea since you cant' get it to rev up much.  If you have been there, done that then like you I would be looking to flush the IP with something to be sure those vanes are not stuck.  Since it runs you could do that. 

Other great ideas?  Did you mess around with the counter clockwise nut and the governor bolt at all?  Maybe it is just limiting out on you.  Then there is the position of the throttle arms on the shaft itself.  Did you rebuild the pump I guess is the question.  If so there may be places as mentioned to look for stuff out of adjustment.  It doesn't take much on these pumps you know that.

[regcheeseman]

Thanks for the ideas, I've tried progressively more retard and it just gets worse - more smoke and less idle and complete reluctance to rev at all, to far on the retard and it wont idle even, filling the garage with thick black soot in minutes.

Flush the IP? Are we talking about ATF?

Counter clockwise nut and govenror bolt??? not sure what nut you mean but by gov bolt, do you mean the bolt the gov weight assembly spins on? If so, yes it was removed, marked first, turns out counted and refitted in what I'm sure is the same position.

The throttle arm is fine on the splines the throttle arm is pulling the throttle plate as expected.

Think I'll dial in some more advance, if I mark it first I can always set it back.

[Patrick]

By all means, try the ATF, maybe try feeding the pump with pressure too. (electric fuel pump), If the vanes are stuck, they may loosen up over time if you can get it to run for a while.

[8v-of-fury]

Which turbo did you use on this Stein motor?

[regcheeseman]

It's a KKK BV39A-0072

Had a play earlier, wound some more advance in, and got to the stage where it was clacking hard for no gains so I set it back to the first bench setting.
At which point it's starting to struggle with the idle and running very quietly so I added a little bit of advance (2 - 3 degrees) to remove the hunting from a the idle.
Then grabbed the camera and got a video clip.

As you can see it's sat idling fine with very little smoke, adding max throttle and the engine speed lifts slightly and you can just make out the cloud of white smoke that quickly grows.

What do I do now??? What's the ATF trick and does it work?

[theman53]

It does seem like it is a governor related issue.

ATF does work, use the cheapest atf you can find, not the newer synthetic stuff. IIRC it is Mercon II or typeF that doesn't have the friction modifier in it. The detergent qualities of the atf will usually free up stuck vanes in pumps, lifters in engines, and clean most everything. Run a bottle of it into the IP and leave it sit for a while.

[regcheeseman]

A while? 5 minutes, 5 hours, 5 days?

Do I just run it through pump once done or suck it back out?