Author Topic: TD injection pump problems (Read 8810 times)

squirrl22 · « **on:** April 03, 2006, 12:42:15 pm »

I replaced all the seals in a leaky injection pump- 1.6 TD- now no fuel is going to the injectors! Plenty of fuel in the pump, even goes through the return line. The new solonoid shut-off works as it should- but no fuel to the injector pipes - any suggestions?
tom

hillfolk'r · « **Reply #1 on:** April 03, 2006, 08:27:19 pm »

all the seals???,,did ya have the top off??did you have the head off???splines for throttle linkage reset ok??sometimes,for testing,,i wont reinstall the return springs,and put on a conventional one, like for a chevy or somethin,,till i get the splines right,,,just be ready to pull the soleniod wire if you mess it up,i also use a metal disc to choke the air to the turbo,if im "afraid" of a runaway,,never had it happen though,,,,but it almost sounds like you are the other way,,,,maxfueland idle screws turned on disassembly,and marked,toput backwhere they were???,hold throttle at wot with inj. lines loose,,crankit,, are ya gettin any any any fuel????get a remote starter button,so u can leave key on,and crank it under the hood,look for squirting,,,man,could be alot of things,,splines not aligned right ,,"new solenoid",,power to the soleniod,,use a jumper to battery directly,,,there will be more posts,,,,

Justin · « **Reply #2 on:** April 04, 2006, 05:46:22 am »

the max fuel screw setting for a TD i think should be 20.4mm from the end of the bolt to the lock nut, and the stock NA settings should be 20.7

this is what the diesel injection shop told me anyway when they rebuilt my pump.

later
Justin

squirrl22 · « **Reply #3 on:** April 04, 2006, 07:05:31 am »

Yes, I had the top off, - I wrapped some wire around the spline/throttle springs to hold "em together, thought I got the splines correct but I will double check this. I will put the throttle at wide open and crank it to see if I can get any diesel from the opened lines.
I was pretty careful about the fuel enrichment screw, I marked it and put it back exactly the way it was before.
Thanks for the reply, guys. Much appreciated.

squirrl22 · « **Reply #4 on:** April 04, 2006, 10:05:15 am »

Well, I opened up the throttle full, cranked it- still no fuel to the injectors- fuel going to the return line, fuel in the pump, no fuel to the injectors. I checked the stop solenoid again- took it out, turned on the ignition- works. I even took an old solenoid, without the little plunger(so there was little possibility of stopping this sucker if I had a runaway) , put that in- cranked it w WOT - nothing. still no fuel to the injectors.
I did have the head off- replaced the rubber seal- but didn't disturb the 2 springs. At least I don't think I did.
Need more help!

Justin · « **Reply #5 on:** April 04, 2006, 11:27:43 am »

I had a pump go bad that had the same symptoms and I tore it apart trying to figure it out and couldnt, I suspect that something got into the head that limits the flow, possibly where the fuel inlet is coming from the fuel cutoff switch

later
Justin

squirrl22 · « **Reply #6 on:** April 07, 2006, 06:41:06 am »

so maybe I've got something blocking m fuel somewhere. Any ideas on how to diagnose why I'm not getting fuel through the injectors lines?
There's fuel in the pump, fuel going through the pump and back into the tank via the return line, but no fuel going into the high pressure injector lines. It isn't the solenoid, I replaced that w a plug, still no fuel. Anyone have a schematic on tha fuel pump?

Justin · « **Reply #7 on:** April 07, 2006, 07:17:15 am »

I am guessing that it is in the head of the pump, as far as cleaning it out i have never tried to clean out a pluged one, so i am not sure, i would recomend cleaning it in Chem Dip then puring fuel though the port that the fuel is introduced (though the solenoid hole and see if you get fuel coming out inside the plunger

another thought pull the fuel stop solenoid out completely like you were replacing it and leave it out, then crank the engine over you should get fuel coming out, if you do then the problem is probably in the plunger head, if it doesnt then you have something plugged between the main body of the pump and plunger head

shoot me an email and I will try to email you a bosch manual, its a fairly large PDF at around 10 megs but its pretty good

later
Justin

squirrl22 · « **Reply #8 on:** April 10, 2006, 09:08:06 am »

Thanks, Justin. I pulled the solenoid stop, I am getting fuel to the solenoid. I've never pulled a head while the pump is still attached to the engine- can it be done?
thanks for the offer of the manual, It's gotta help!
tom

Justin · « **Reply #9 on:** April 10, 2006, 09:35:55 am »

not the cylinder head

the cast iron head on the pump.

it can be pulled off while still on the engine but it may be a pain in the but to put it back together, you might as well pull it off of the engine and work on it so that you dont loose the springs, they are the hardest part to put back together on these things

later
Justin

squirrl22 · « **Reply #10 on:** April 17, 2006, 11:41:37 am »

Here's a question: the advance device on the fuel pump is non-operational (you know, you pull the lever to change the injection timing when the engine is really cold) could this somehow be blocking the fuel from entering the head?

Justin · « **Reply #11 on:** April 17, 2006, 12:04:26 pm »

well its not good that your timing piston is not functioning i dont think that is your problem. when you say it doesnt work though what do you mean? is it when the engine is not running the timing piston is already pushed in and when you pull the lever its really easy (I ask this since I am assuming you still cannot get it to run)

after looking at the fuel flow diagrams for these pumps I don think that your timing piston is the problem getting to the pump head, but if its is siezed up in the timed position then that would probably mean the pump had a lack of lubricity and if thats the case then who is to say the plunger head in the pump head didnt do the same? if thats the case then it would explain the not running but vanes are still pumping fuel.

thats My 2 cents

later
Justin

JBTDI · « **Reply #12 on:** May 14, 2006, 03:46:20 pm »

Squirrl,
Did you ever figure this out?
I was just helping a friend to start an '85 NA Golf with the same symptom. His pump is leaking from the quantity adjuster shaft though. I know on a TDI pump, if the quantity is set too low you can cut off the fuel but I don't know what would have to happen in these pumps to do it.