Author Topic: VW Golf 2 1,6 TDLLK SB modifications  (Read 245 times)

January 05, 2020, 08:13:40 am

1 6 D

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VW Golf 2 1,6 TDLLK SB modifications
« on: January 05, 2020, 08:13:40 am »
Hi,

This is my first post. I want bring my old Golf for daily. But I can't set engine to run properly after some mods.

What I have done:
- cylinder head gasket from AAZ
- boost set up to 1.1 bar
- whole new exhaust including casted downpipe have 60mm now and 2 mufflers from GTI 16V
- boost pin turned to max

After that engine runs good. After last mod with injectors from 1,9 TD AAZ engine haven't power now. AAZ injectors have nozzles from my SB because they are in good shape. Opening pressure in injectors is 175 bar now. I can regulate actual pump or I have swap pump from AAZ or only cam plate plus some regulations? Or only change in timing will health this engine?
« Last Edit: January 05, 2020, 12:50:44 pm by 1 6 D »



Reply #1January 05, 2020, 03:40:02 pm

ORCoaster

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Re: VW Golf 2 1,6 TDLLK SB modifications
« Reply #1 on: January 05, 2020, 03:40:02 pm »
Could it be that your Injection Pump, IP, is not capable of producing 175 bar pressure?  The previous injectors may have been only 135 bar. 

If the only thing you have done is change injectors then I would suspect a poor pump.  They do wear and there are a few things you can change to get past that wear.  But you need to be a fairly good mechanic to work on the pump without messing it up forever. 

Yes it is just metal and rubber parts but knowing when to pull and when not to is key to getting one apart without snapping the metering plunger that does much of the high pressure work.
Rabbit repairs to body damage need attention before trying to sell it in the spring

Reply #2January 05, 2020, 04:05:27 pm

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Re: VW Golf 2 1,6 TDLLK SB modifications
« Reply #2 on: January 05, 2020, 04:05:27 pm »
Fabric injectors were 155 bar.

Reply #3January 05, 2020, 04:40:19 pm

ORCoaster

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Re: VW Golf 2 1,6 TDLLK SB modifications
« Reply #3 on: January 05, 2020, 04:40:19 pm »
You have set the new injectors to be at 175 bar if I follow your thread.  That means you have to build more pressure to get them to open compared to the last ones you had in the engine at 155 bar.  The IP will need to build for a longer time to get it that high.  That will take time and what might be needed here is to advance you IP timing to account for that longer build time.

For an experiment in timing loosen all the IP hold down bolts, all four leaving the one in front just a bit tight.  Then start the engine and hold the IP still and loosen that last bolt.  Now grab the top of the IP and push it towards the engine, giving it more advance timing.  That should line up the shot of diesel going to the cylinders a bit better with the top of the piston coming up. 

If that raises the RPMs then lock the IP pump down, adjust the idle to a lower level, spec, and try driving it.  My guess it will perform much better than when you first installed the new injectors. 

If this does the job you will need to time the engine differently than in the manual.  Only trial and error will get you to the proper time for your modified setup now.  Measure what it is after the test. write that down, move it a bit more using the dial gauge and write that reading down.  Continue a few of these changes and drives over about a week until you can figure out if 1.4 or 1.7 or 1.0 is where the engine performs best. 

Good luck and keep us up to date on what it is you are doing and how it is working out. 
Rabbit repairs to body damage need attention before trying to sell it in the spring

Reply #4January 05, 2020, 04:52:38 pm

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Re: VW Golf 2 1,6 TDLLK SB modifications
« Reply #4 on: January 05, 2020, 04:52:38 pm »
Thank you for your answer. I forget to write that during drive and when turbo gives boost it works almoust like on previous injectors. i will write if engine will start work properly.
« Last Edit: January 05, 2020, 05:57:33 pm by 1 6 D »

Reply #5January 05, 2020, 07:47:17 pm

fatmobile

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Re: VW Golf 2 1,6 TDLLK SB modifications
« Reply #5 on: January 05, 2020, 07:47:17 pm »
White smoke?
 Does the new pump have a cold start lever?
 How does the sound change when you pull it?
Tornado red, '91 Golf 4 door,
with a re-ringed, '84 quantum, turbo diesel, MD block