Replacement motor wont run or even fire.

[regcheeseman]

As a potted history, engine bought as 'a runner' from a scrapyard - but not heard running

It's a intercooled GTD lump

Anyway, last night I finally got my motor in a state to run,

No intercooler hoses - so I just bypassed the turbo and put an air filter on the intake stub

Battery fubared - so Toyota and big jump leads used

Glow plug circuit not working, so warming up the plugs by reaching over to fuse box and plugging glow plug lead onto main 12v feed

Fitted hand bulb primer - so primed the pump.

Cracked open all the injector fittings and turned her over till diesel flowed - I'm not getting very much from each cracked diesel fitting but should I?

Anyway the starter motor was sluggish because of the leads/battery but I never got the slightest sign of life from the motor. Not a single splutter in forty minutes of on/off cranking.

The motor is turning over slow - maybe this is the problem? It no slower than when the NA 1.6 was fitted and that would fire with or without glow plugs.

Pump Timing is spot on 1.00mm

Couldn't double check valve timing exactly (because of time constraints) but I timed the motor up before fitting it.

Compression seems good because the starter struggles. And turning the motor manually it seems 'right'

Anybody got any ideas?

edit: post moved from IDI section

[regcheeseman]

I had a choice of two starter motors, one from a gasser 1.5 and one from an NA 1.6 D.

I don't know which was which  :roll:

The short fat starter motor had decent brushes and looked the beefier of the two

The long thin starter motor had worn brushes and looked weedier.

I chose the short fat one - have I picked the gasser one?

[BlackTieTD]

i think the fatty is the one you want.
are you sure the glow plugs are working? i know i've blown all 4 of them before screwing around bypassing the fusable link  :roll:
i don't think it would be that cold over there right now but who knows... if the glows are all shot that could be it?

[tadleyjane]

if it is turning over slowly it makes it even more difficult to fire/start.  can you pull start it?  it rarely requires glowplugs if it will turn over that fast.  good luck

[LeeG]

I would describe my diesel starter as long and skinny.
Do you have good connections to the starter and grounds on engine?  Your old battery could be shorted inside and stealing juice from the Toyota, not leaving enough for starter?  These guys need a hot battery to spin, there is a minimum cranking speed, I think in bently.  When my battery got weak, I had a real b*tch starting, it sounded like it was spinning fine, but it wouldnt fire.  New battery fixed it.

so warming up the plugs by reaching over to fuse box and plugging glow plug lead onto main 12v feed
 

Are you sure you have the right wires at fuse box?  When my fusible link went in cranked like crazy without any signs of even farting.  To bypass that I put my jumper cable right onto the first glow plug connection under hood.  -Not sure if that is what you described above or not.

[regcheeseman]

Update,

I fixed the glow plug circuit so it now operates correctly - I'm sure the glow plugs are glowing - they were fine before installation, they draw a hefty current but don't blow the fuse.

I fitted a 100% straight to the car to eliminate the jump leads and the starter is slow, it definitely is from the petrol 1.5 golf.

It doesn't seem too slow, my old NA would fire even if the battery was so flat the motor would barely turn over.

I can't pull start it at the moment (no gearbox linkage!) The brakes need fluid and bleeding too. May get those jobs done and try it though.

After I had to return the battery to my next door neighbour, I checked the solenoid - I couldn't remove it from the pump but it clicked when powered - can I assume it is OK.

FINALLY..... I have a primer bulb fitted in the feed pipe, with the solenoid open, should the primer pump fuel through the pump and out the return?