please help gtd injectors garret t3 installed now smokes - IDI Engine - VWDiesel.net The IDI, TDI, and mTDI source.

• please help gtd injectors garret t3 installed now smokes by bustedfoxwagen on 11 May, 2007 00:26
• ok here is the deal has the stock turbo on my 92 eco diesel installed my gtd nozzels everytime i start it it runs rough and smokes like crazy i drive it a mile and come to a stop idels smooth and no smoke?? any idea what it is?
  
  and whats a safe bost level to run with the t3? ran 23psi on small one runnin 10 now need more  :lol:
  
  pics of install
  
  before and after
  
  
  
  
  
  
  my rigged oil return line....
  
  
  
  
• #1 by bert on 11 May, 2007 14:16
• Was the T3 brand new? it looks like it,ive got a T3 on my AAZ and it runs 11 psi and it really pulls well,try pump timing,now the injectors are new,they will pop at the right pressure,the old ones probably earlier as they wear,
  Bert
• #2 by bustedfoxwagen on 12 May, 2007 00:02
• Quote

  Was the T3 brand new? it looks like it,ive got a T3 on my AAZ and it runs 11 psi and it really pulls well,try pump timing,now the injectors are new,they will pop at the right pressure,the old ones probably earlier as they wear,
  Bert

  
  
  got the t3 and manifold off ebay NOS i was told pump timing also i think its set at 100? i don;t know that number come to mind
• #3 by subsonic on 12 May, 2007 07:52
• Dude,
  I dig the white walls!!  Did someone pimp your ride :shock:  :lol:  :lol:
  I do like them though.
• #4 by bustedfoxwagen on 13 May, 2007 10:16
• Quote

  Any air bubbles in the clear fuel line?
  
  Any pump or injector leaks?
  
  Andrew

  
  
  i didn't see any bubbles in the clear, well mine use to be now its a hazed brown... and my pump has no leaks, only leak it has is an oil leak cause mu pan is beat to crap.. here is a video of how it smokes the first start up everyday
  and yes it does blow smoke rings
  
  
  edit.
  and i just put mu boost controller on!!! and WOW it comes alive after 10psi!!! keeping it a 15 now and i love it, sorry i was excited on how good it pulled
• #5 by Vincent Waldon on 13 May, 2007 13:28
• One thought:  did you (or whoever redid the nozzles) pop test them and re-calibrate to 155 bar
• #6 by vwmike on 14 May, 2007 05:21
• Is your glow plug system working properly?
• #7 by sethyboy85 on 14 May, 2007 09:10
• my dad's car blew smoke rings and it was a bad injector, you could feel it when driving every so slightly...
• #8 by Wingaman on 14 May, 2007 09:18
• Poptest your injector asap before engine damage.
  
  I got a complete shipment of those nozzles(GTD DNOSD274) the last month and 90% was bad.
  
  I bet a bad nozzles or incorrect installation.
• #9 by bustedfoxwagen on 15 May, 2007 10:27
• what is pop test??? i don't know what that is? when igot my nozzels one was bad the shaft wouldn't slid and the other 3 did, so thry sent me another and it was good,
• #10 by subsonic on 15 May, 2007 10:51
• Pop testing is like saying calibrating.  It is describing the test process they use on diesel injectors.  Injectors are supposed to open to let the fuel spray at a specific pressure.  The opening pressure can be adjusted by small shims inside the injector.  They change the tension on the spring.  
  Pop testing is when they hook up the injector to a device where the the pressure is increased until the fuel sprays out.  A pressure guage will record the breaking pressure.  The injector is then shimmed to bring the opening pressure in line with spec's.  The 1.6td injector spec is 155 bar.  
  If anyof  the injectors opening pressures are out of spec, they will inject fuel to early or late in the cycle.  That will cause your engine to run like ass.  If you call around to any diesel shops near your house you should be able to find someone to pop test your injectors for a small fee.
  
  Jim
• #11 by Vincent Waldon on 15 May, 2007 11:34
• To put it another way...injectors have two main parts:
  
   - a nozzle which decides how much fuel to inject
  -  a biggish spring and a shim that sets the pressure that the nozzle turns on at.
  
  Nozzle:  how much fuel
  Spring and shim:  when the fuel is injected, based on pressure
  
  So, you've replaced the nozzles... we're asking if you also had the spring/shim combination checked and re-calibrated as required ? Basically each injector is hooked up to a test bench (some of us have built our own) and checked for the "breaking pressure" (when does the injector open... should be 155 bar according to VW).  If the pressure is wrong (and it often is after a full nozzle replacement) the injector is disassembled, the shim is changed, and the process repeats itself.
  
  While the breaking pressure is being set the nozzle is also examined for the right spray pattern.... if the nozzle is defective or dirty it will be obvious.
  
  Like the previous poster said... a local shop will likely be able to do this for you for cheap or even free.... don't forget to at least buy your new heat shields from them !
  
  
  Vince
• #12 by Wingaman on 15 May, 2007 11:49
• I cannot add anything else hehehhe  
• #13 by bustedfoxwagen on 15 May, 2007 23:40
• wow guys you have been more than helpful and seem to really know your stuff i know mopars like that so if you have them and need some info ill be glad to help  :lol: