max rpm 2900

[Kudagra]

So i have an 85 Jetta mech head 1.6td with a Giles pump. Feeding it is a 93 GM 6.5 td lift pump. I cannot set the high RPMs any higher then 2900rpm. When bleeding the air.from the injectors the fast idle cam linkage fell apart (I never touched it) and the sporting the spring inside fell off.  I put it all back on with the pump installed (not a fun task) then it would not start till i put the throttle at about 25-30%. I removed the pump, took off the top cover and reattached the spring. Re assembled the pump, installed and bled the air. Now the engine starts and idles but I all can't get more then 2900rpm. Its like its hitting the governor

Any idea what under the cover might not be right and causing this problem?i have clear hoses on the inlet and outlet of the pump. I have no air in either.

[burn_your_money]

You are probably 1 or 2 splines off on the throttle shaft.

[Kudagra]

Not sure. It did that before I took it apart. That would mean Giles put it together wrong, which I find hard to believe. It reaches 2800 when the throttle is at about 50%. Then it just does nothing else any more then that.

[burn_your_money]

Try running it off a jerry can and see what that does. Also, any restrictions on the air intake or exhaust?

[Kudagra]

Not even an air filter on the turbo. Im going to put a fuel pressure gauge on the inlet next week. I'm just wondering if there could be anything that came loose inside when that linkage came apart our when I put it back together

[burn_your_money]

Even without that idle lever hooked up you should still be able to rev a Giles pump further than your engine could handle.

Did you have to fiddle with the max fuel screw?

[Kudagra]

Nope. Didn't fumble with any set points. It fires right up. It revvs quickly..but it hits a wall at 2800-2900. Just fyi I'm using a photo tach and 2 reflectors on the injection pump pulley.

[8v-of-fury]

You marked the orientation of the throttle shaft to throttle arm as well?

Not sure. It did that before I took it apart. That would mean Giles put it together wrong, which I find hard to believe.

He is only human, it is possible. You should take a good picture and scribe lines where it is set now and play with the settings. There isn't much else that could give you your issues.

Is it a TD pump?? I have an idea.. if the limiting pin in the lid is stuck and not allowing the pin to push out against the boost pin when it moves down under boost pressure.. you should effectively be left with about as much fueling as you have. It is definitely worth a shot my friend.

[jboogie13]

FWIW, this is similar to what happened when i got some wet fuel.

+1 on the jerry can/purge can.

[Kudagra]

I take pictures. This is before anything was disassembled.

Sorry...resized.

[8v-of-fury]

I can tell you right away, the way you have it set up right now is all sorts of effed-up. AKA wrong. lol.

Set that to the middle line and readjust the max screw and the idle until you get it runnin right.

You are going to have to back the max fuel screw WAY OUT. I suggest like the last two threads and start from there, after you readjust to the middle line on that spline. Try and crank, no go? Turn it in a full turn etc. etc. Until you get it to idle or runaway a bit and then back it out. From there it just needs the idle set and you are golden.

[8v-of-fury]

It is either that, or the idle needs bottomed out and the fuel screw turned way up. I have run them this way before, and you get a lot of fueling.

[Kudagra]

Ya know...that doesnt make me feel good. I never messed with any adjustments or linkage on this pump. It was never even ran since I paid $1100 5-6 years ago. I installed it and set the advance. Cranked it enough to bleed the injectors. It ran and the linkage fell apart. Now you are telling me the throttle shaft was installed wrong? Ugh. I know no one is perfect but damn. I'm just going to figure it out. No accusations. Giles is a good guy and I'll still recommend him over anyone else. Something silly happened here but I'm not sure what.

I'm going to reset the shaft splines (I thought it was odd the lines didn't line up) and I'll go from there.

[theman53]

I spoke with Giles about mine, I suggest you do the same. He worked on my pump at a discounted rate as he said he would stand behind his work. I cannot speak for him but I would almost guarantee that he will help you out if you contact him first. I bet he would tell you to try all these suggestions first and then go from there. I think everyone is on track here, but it would be nice to know from the guy that built it.

[burn_your_money]

If you are getting a reading of 2900 off the pump pulley then you have no issue.

I wouldn't adjust anything before talking to Giles.