1.6 turbo lack of power in 3rd & 4th gear

[zukin]

new to this board, have a 1.6 turbo diesel in my samurai.
did the conversion beginning of the summer.
a couple weeks ago starting have with no power under load, when I shift from 2nd to 3rd or 3rd to 4th engine lugs between 2500 - 4000 rpm.
here are some thing I have tried, bypassed the fuel system ( hooked up a jerry can directly to the injection pump)
checked the injection pump, carm & cranks timing, checked injectors (cracking open the fuel lines while engine is running)
checked turbo for boost, got 9 psi boost.
kinda running out of ideas anyone have any ideas or suggestions?
thanks in advance

[745 turbogreasel]

Low power is usually air in the fuel, possibly from the pump input shaft seal.  do you have any bubbles in the return line.
fresh fuel filter?
Any kind of lift pump?
Smoke with this condition? vs. before?
Any chance you are sucking an intake tube shut  at full  load?
Do you run  diesel only, or other stuff?

I'd go through, and touch every hose clamp in the fuel system  for tightness.

[zukin]

just ran a clear fuel line from fuel filter to injection pump, no bubbles.
like I said on previous post, I had bypassed the entire fuel system (fuel tank, lines & fuel filter) ran a jerry can.
what is a lift pump?
no smoke before or after the problem.
which intake tube are you referring to? the one that connects directly to the turbo? if that is what you are referring to no.
running only diesel for now.

[theman53]

did you run clear return lines into your can? The pump front main seal can leak as he suggested and you have no air coming in, but you have air leaving as it sucks it in from that seal.

[TylerDurden]

To embellish the above, a clear line on the OUT can reveal if the IP seals are leaking on the lift* section.

*The IP has a lift-pump section that pulls the fuel in and pressurizes the case, before the HP section of the IP sends the fuel to the injectors. The lift section is a vane-style pump.

[zukin]

is there a way of diagnosing the injection on the engine without taking off the engine?
I am kinda leaning towards it as the problem.
just want make 100% sure before I pull it.
unless anyone else has any ideas I could try.

[8v-of-fury]

Is the BOV in the intake opening and you are loosing all your boost under high load pulls?

[zukin]

where is the bov, how can I check it?

[8v-of-fury]

Its on the intake manifold, on the top side of one end. It was making my 1.6 TD a complete dog, boost would build and then all power would just drop off.

Plug it with something and go for a drive.

Another thing, are you sure your LDA in the pump is adjusted properly? Have you messed with any of the pump settings?

[bajacalal]

If I did a Samurai build I would run an auxiliary lift pump. The VWs did not have a lift pump. But other vehicles with a VE pump like Cummins did and I think the internal lift pump can only suck so hard and if the fuel has to travel real far or has to overcome some elevation (low fuel tank and high mounted engine) it just can't do it.

But your symptoms do sound like boost is escaping and the BOV is a suspect component, along with it's o-ring that seals it to the manifold, as are any hoses, gaskets, etc., between the turbo and engine...

[zukin]

any chance you could post a picture?
what am I plugging?

[8v-of-fury]

http://www.vwdiesel.net/forum/index.php?topic=2554.0

[bajacalal]

Here you go.

I take no credit for the original photo.


The boost enrichment system is something else to look into though. If you are not getting the full amount of fuel, all that boost really doesn't do much, which is why the question was brought up about smoke. If it is smoking a lot of black smoke under medium throttle it is not getting the required amount of air. If it does not smoke at all under full throttle, it is probably not getting enough fuel.

[zukin]

bit of a update problem not really fixed, eliminated injection pump.
a buddy gave me a rebuilt one, don't know if it is an adjustment or what, engine will not
unless the cold start is pulled out even when he engine is warm.
what would be the best next step, remove and plug bov, replace turbo?