Problems with 11mm pump on a 1.6TD

[Alcaid]

Hi,

We're testing my hybrid 1.6TD pump with an 11mm piston (built by Dieselmeken in Sweden) on a friends car, but it's not working correctly as the pressure in one (or more?) of the injector lines does not drop sufficiently to close the injector so the cylinder compression blows up through the injector! The pump is newly built and run in a test bench so that one is working for sure. It's something with the combination of delivery valves, hard lines and/or injectors that doesn't work together the right way.

We've tried both stock 1.6TD injectors and AAZ two stage injectors and it's not working correctly. The 11mm pump head and delivery valves are from the same donor pump, hard lines are stock 1.6TD.

As seen on the video in the link below it foams on injector #2 while the nut is cracked, tightening it again stalls the engine...

http://www.youtube.com/watch?feature=player_embedded&v=1Hxlej30SJg

[rallydiesel]

It's always #2 line, even with different injectors?

[libbydiesel]

Swap that delivery valve with another one and see if the problem moves.

[Alcaid]

With the AAZ injectors the problem moved to injector #3 and #4 so don't think a specific delivery valve is faulty...

[Alcaid]

My friend just found the solution, he had used the banjo fittings from his stock pump and they where not the correct ones for this pump!

[R.O.R-2.0]

My friend just found the solution, he had used the banjo fittings from his stock pump and they where not the correct ones for this pump!

that makes NO SENSE at all..

how did banjo fittings make it not run correctly?

[Alcaid]

My friend just found the solution, he had used the banjo fittings from his stock pump and they where not the correct ones for this pump!

that makes NO SENSE at all..

how did banjo fittings make it not run correctly?

Agreed! Not much difference to them but Dieselmeken who built the pump gave us this tip, and it worked.

[Harky]

Out banjo? It helps control the internal pump pressure does it not?

[Alcaid]

It was the banjo on the return line that was changed

[R.O.R-2.0]

It was the banjo on the return line that was changed

so, you guys had the wrong OUT bolt in the pump.. right?

[Alcaid]

It was the banjo on the return line that was changed

so, you guys had the wrong OUT bolt in the pump.. right?

Yep, the out bolt of a 9mm pump just didn't do the job right with the 11mm pump

[Harky]

I'm using a 9mm OUT bolt on an 11mm (albeit Peugeot) pump.

AFAIK the OUT bolt helps regulate the Internal Pump Pressure, are you by any chance using the 11mm pressure regulator?

Good its all sorted now anyway though

[Alcaid]

I'm using a 9mm OUT bolt on an 11mm (albeit Peugeot) pump.

AFAIK the OUT bolt helps regulate the Internal Pump Pressure, are you by any chance using the 11mm pressure regulator?

Good its all sorted now anyway though

To be honest, I don't know what parts has been used. I sent a 9mm VW GTD (80hp) pump and an 11mm pump from a Kia to Dieselmeken in Sweden and asked him to make me a 200hp pump

He has previously dynoed 200hp with 110cc of fuel, my pump was capable of 130cc in the flow test bench 

[snakemaster]

that pump wants the bolt from the 9mm pump , as the other one will make to much Internal Pump Pressure and it could sit on the revs to, what cam plate is the pump running