1.6L IP Pushing fuel out Inlet Banjo

[Estacaco]

Hello, Long time listener first time caller  

I have owned a 1992 1.6l TD Jetta for a couple years now and recently rebuild and changed me IP. The rebuild went pretty well with all the info I was able to find. The only problem I'm having now is getting the car to start again. I've almost had it a couple times. I've filled the filter and the pump with fuel and it almost starts even. But when I had someone watching my fuel in line on the pump they said it was pushing fuel backwards and foam flowing out the inlet as well. Tell me there's something that could cause this besides me screwing up the rebuild  
Pics for clicks.

When I swapped the windshield.



Goop on the diaphragm when rebuilding pump



Some pics of the rebuild








Timing!




Thanks for looking! Any help appreciated

[ORCoaster]

My TDC mark doesn't look anything like yours.  You sure about the position?  I have a mark that I painted with some white paint so it is easy to see on a cloudy day.  Turn the engine back and then forward and see if you come up with something that looks more like a line or a 0 mark.  Could be that it is just still out of time. 

Do you have the dial gauge to measure with once your index marks are all lined up straight? 

[Estacaco]

Yes of course I have all the timing tools. I try not to dive into things TOO half a$$ed I believe it is the correct timing mark as I had the car running using it with another pump but unfortunately that pump kept kicking out at 2500 RPM

[8v-of-fury]

That is most certainly the TDC mark. I do believe a line or a "zero" means you have a gasser flywheel on there?

My 91 flywheel looked just like that. If it was a gas flywheel in the op's engine, the TDC mark would be just to the right of what he's got right? So really what other marks are there on there for it to be?

[ORCoaster]

http://www.vwdiesel.net/forum/index.php?topic=16960.0

Checked this for a better picture and didn't see it but I have an 81 so the flywheels may indeed be different by then.  Should I picture mine before the sun goes down? 

DAS

[Estacaco]

If i keep rotating in either direction there's two large rectangular protrusions on either side of the mark. I'm certain it's TDC as I had someone with me that has the same mark in their wagon helping me out.

But I hardly think that's why my pump is forcing fuel backwards through the in hose lol.
It also does the same if ran out of a jerry can.
If I fill the pump with fuel ( I fill the fuel filter, run the return fuel hose into a bottle of diesel. and blow into the now open pre-heater valve on the filter to displace the fuel and force it into the pump till I see solid fuel in all lines.) and the filter It almost idles.

[libbydiesel]

If the fuel is flowing backwards through the pump then you installed the outer ring of the vane pump incorrectly.  The hole should be on top with the fatter side to the left.

[Estacaco]

If the fuel is flowing backwards through the pump then you installed the outer ring of the vane pump incorrectly.  The hole should be on top with the fatter side to the left.

Are you referring to this?

[libbydiesel]

Yes.  That is the way it should be.  The only way I know of to have the fuel flow the wrong way through the pump is to flip that outer ring over so the fatter side is to the right. 

[8v-of-fury]

Is that your pump pictured??

[Estacaco]

You've gotta be kidding me...Anyone know any easy way to put those throttle springs back on? That was really the only painful part of the whole job.

No that is not my pump pictured but the one in my OP is.

[Estacaco]

Unfortunately I don't have a picture of the ring in question...

I guess it's for the best as I nicked a bushing trying to get the old front seal out and I already bought the replacement bushings,

[libbydiesel]

I made that mistake once despite knowing better, which is even more shameful than if you're oblivious.  After working by myself messing with the pump adjustment screws for an hour or so, I had my wife crank the car over while I watched the fuel.  I immediately knew what I had done and laughed out loud at the mistake.  It took me three hours to pull the pump, disassemble it, flip that piece over, reassemble, install the pump and get it purring again.  It was only a slightly painful mistake.

Just consider the last time you had the pump apart to be good practice for this time.  The bolts shouldn't be stuck too badly this time either.  Also if you think the 1.6 accelerator springs are hard to install, then you should try the AAZ pump springs just for perspective.  Best hint I have is to use a pair of needle-nose vice-grips.

[Estacaco]

Last time I did it with my hands and a Flat head screw driver.

[ORCoaster]

I use vice grip needle nosed pliers to grab a piece of the spring and bring it under the tabs that retain it.  I do the bottom then the top one last.  I get the 10 mm nut started but keep it just lose enough to be able to get the spring under it.

Timing marks on my Diesel:

http://i1087.photobucket.com/albums/j475/Orcoaster/IMG-20120530-00220.jpg

http://i1087.photobucket.com/albums/j475/Orcoaster/IMG-20120530-00219.jpg