Author Topic: It's alive!!!! Kinda... (Read 2284 times)

Black Smokin' Diesel · « **on:** May 21, 2007, 08:35:36 pm »

For the first time in a month, my TD engine ran (albeit only for a few minutes).

I had to replace the head so I took the opportunity to do the crank, cam and intermediate shaft seals, replaced the shifter bushings (really easy when the head is off), replaced the oil pan with a custom made baffled pan, installed a crank scraper and fixed that leaky oil cooler/heat exchanger.
The head got mercedes injectors (135bar), new glow plugs, new lifters, slight P&P, new gaskets and a rebuilt K24 (thanks to burn_your_money for the working wastegate and compressor/turbine wheels). I wish I could have done a cylinder hone with new rings but that was out of my budget. Anyway the cylinder walls looked good and compression was good.
I used the 1.9TD HG with new timing belt and tensionner. I also got my dirty hands on an aluminum thermostat housing from an early MK2.

So today after filling up with 10w30 synthetic oil and a 65/45 mix of coolant, I tried to start the engine.

Turns out I had to retime the pump and fart around rotating it to get it to fire. Mind you that I don't have the dial indicator to do it properly

Now it runs but it's really rough, smokes like a steam engine and sounds like a big rig :lol: There are small leaks around the injectors and oil return line on the turbo (what a *** to install :? ). They should be taken care of tomorrow.

All these symptoms are IMO related to timing. I'll be going to a VW garage this week to get it timed to NA specs since the injectors are 135bar and not 155bar units. I'll also have the pump propery adjusted, idle is a bit high.

Now I noticed the timing belt was wandering a bit on the pulleys (about 2mm) and that the intermediat shaft pulley was making a nice cut in my brand new TB!!! Anyone knows why it's wandering like this? All the pulleys seem to be aligned. I read a short time ago that the later intermediate shaft pulleys weren't "grooved" like the early ones. I happen to have one of these flat IS pulleys. I think it might solve my problem, or at least stop my TB from being cut like this.

For this reason and the leaky bits, I didn't take the car for a ride. I did notice the engine was heating up pretty fast (1/4 of the gauge in a few minutes at idle). Could this be a side effect from the bad timing?

Here's a picture of the car the day I bought it.

Vincent Waldon · « **Reply #1 on:** May 21, 2007, 10:24:56 pm »

Yup, everything you've described could be associated with leaks and expecially timing... my suggestion: don't waste any more of your time until those two are looked after. Good chance things will look up !!

Vince

Black Smokin' Diesel · « **Reply #2 on:** May 22, 2007, 07:37:15 am »

Quote from: "Vincent Waldon"

Yup, everything you've described could be associated with leaks and expecially timing... my suggestion: don't waste any more of your time until those two are looked after. Good chance things will look up !!

Vince

Thanks! Leaks will be taken care of today and I'm having the car professionnaly timed in a VW shop thursday.

I'll be replacing the IS pulley with the non-grooved one I have today as well. I'll also take a few pictures of the engine bay and car as it's a bit different than when I bought it, just for fun

Black Smokin' Diesel · « **Reply #3 on:** May 22, 2007, 09:45:50 pm »

Got the leaks fixed (I hope) and replaced the intermediate shaft pulley. The engine is extremely noisy and has very little power.

I wasn't able to drive it home because of some wiring problem on the battery terminals which I wasn't able to fix because the hood cable thought it would be a good time to snap.