Need a little help on my bosch 1.6TD VE injection pump please

[3benny3]

 Tore my 1.6TD down to a short block in the car the other day to change a bunch of seals and gaskets but mainly to reseal the pump. As it had started leaking a quick drip. With the pump on the table I resealed most of it, only pulling the head and gov/boost assembly. After putting everything back together when I go to crank it up, it goes straight to wide open (I turn it off right at around 3000rpm, so not sure how far it would go) I believe the problem to be with the gov or throttle? Comparing to pictures of it and others on the internet it appears correct and everything fit ok, but obviously something is wrong. Has anyone else had this problem, or know what I may need to check?

Any help appreciated!

Thanks, Ben

[vanbcguy]

Good chance the accelerator lever isn't indexed properly on the shaft, or the max fuel screw is in too far, or a combination of both.

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[libbydiesel]

^^^Yup.^^^

Did you mark the accelerator lever to shaft orientation?  Did you keep track of how far in the max fuel screw was? 

I'd start with turning the max fuel screw out a couple turns.  Report back.

[3benny3]

Max fuel screw is the same to a 1/16 a turn, throttle lever was scribbed and put back the except same as well as far as I can tell. Will upload some photos later to see if anything just jumps out as a problem. Thanks for the inputs!

[libbydiesel]

Rotate the max fuel screw CCW 2 turns and try starting it again.  Report back.

[3benny3]

Tried backing it out 3 turns earlier today, but no change. Also moved lever tied into the cold start timing lever on engine head side of pump (name?) to remove tension on the spring pulling lever beside gov (thinking it increases/decreases idle when cold start lever is activated) Will check everything again and do some more testing and report back after work and add the pictures. Thanks

[libbydiesel]

With the max fuel screw backed out the two turns, pull the accelerator lever off and try running it.  If it still over-revs, the issue is internal and something like the control lever assembly not indexed properly with the control collar or the governor spring capsule not attached properly to the control lever assembly, etc...

[3benny3]

Have tried backing out the max fuel, turning the splined throttle shaft clockwise for full idle. Same thing though fires up and off it goes.

Appears that everything is sitting and working correctly, but maybe you can see something that is off? I will do some more testing in the morning, I'm sure it's something stupid simple that I'm just not seeing or am doing backwards.

[libbydiesel]

That all looks right to me.  Look down into the diesel while you move the control lever and make sure it is indexed correctly into the control collar and that the control collar moves properly. 

[3benny3]

Yep gov lever notch was in the hole in the collar and and moved back and forth on the plunger as the lever was moved back and forth. Will hopefully get to play with it some tonight and in the morning and will report back, really not wanting to pull it again as it's gotta be something dumb but may have to. Thanks again for the insights and pointers

[carrizog60]

is the governor assembly /accelerator shaft rotating to the correct side?

[3benny3]

 I believe the throttle shaft will only fit one way in the housing. Confirmed for sure that the gov lever is sliding the collar on the plunger freely and is attached via the notch/hole (not off to one side). Also with the max fuel screw all the way out, the throttle all the way closed, and the advance lever all the way off so not to trigger high idle. Crank the car and it still climbs past 3500rpm. Must be something wrong behind the head? Is there something that would cause the throttle/gov system to have no affect?

[burn_your_money]

The governor/throttle assembly is sitting right on top of a black collar that goes over the governor shaft. Make sure that that piece can move freely back and forth (moving the flyweights with it).

[3benny3]

 Ok problem solved, thanks for all the help! Everything was/is correct as far as I can tell. But when installing the top with the boost lever and max fuel screw one or the other or both were interacting incorrectly with the gov lever causing the WOT. This happened installing the top about 4 or 5 times until I was more observant the last time so apparently rather easy to do. You can feel the difference in the throttle shaft with everything back together except for the throttle lever return springs as it is a smoother more pronounced pull against the gov springs and has a bit more travel.Only problem now is a unreliable idle rpm, can set idle but after a rev it may or may not return back as low. Has happened before when the hard lines weren't air free, but will see after some driving.

[vanbcguy]

Back out the residual fuel screw a hair (the one the accelerator lever rests on at idle) - there may still be a little tension on the transition spring. I've experienced what you are describing with that style of pump before.

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