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Engine Specific Info and Questions => IDI Engine => Topic started by: Vwcaddy81 on May 12, 2018, 08:44:59 pm

Title: 1.6td with 1.9 head
Post by: Vwcaddy81 on May 12, 2018, 08:44:59 pm
I just rebuild a cy 1.6td engine. New everything. Had hans auto rebuild the pump with a aaz plunder. Timed it to 1.00mm and .95mm.  I cant get it to start. It just pops every now and them smokes that's it.  I need help I'm lost. First vw diesel. She getting fuel and air
Title: Re: 1.6td with 1.9 head
Post by: Ian0391 on May 12, 2018, 08:52:12 pm
I just rebuild a cy 1.6td engine. New everything. Had hans auto rebuild the pump with a aaz plunder. Timed it to 1.00mm and .95mm.  I cant get it to start. It just pops every now and them smokes that's it.  I need help I'm lost. First vw diesel. She getting fuel and air
I'd be worried about that hans pump. I bout a k14 turbo centre section from them and the compressor but hadn't even been tightened, and another time bought a timing belt tensioner and when I torqued it to the vw spec it cracked in half.

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Title: Re: 1.6td with 1.9 head
Post by: Vwcaddy81 on May 12, 2018, 09:15:42 pm
I had this pump rebuild
Title: Re: 1.6td with 1.9 head
Post by: Ian0391 on May 12, 2018, 09:30:09 pm
I had this pump rebuild
Yeah that's why is he worried, they're known for shoddy workmanship. The turbo I got was a fresh build and they didn't even tighten the most important nut. I've heard many other horror stories about them since also.

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Title: Re: 1.6td with 1.9 head
Post by: Vwcaddy81 on May 12, 2018, 09:47:36 pm
I'll be pissed if it's the pump!!  I have a pump on the 1.6 na that I took out. Could I swap them just to see it it will run??
Title: Re: 1.6td with 1.9 head
Post by: libbydiesel on May 12, 2018, 11:14:04 pm
I have heard 10+ stories of pumps that were 'rebuilt' by Hans that would not run.  I have never heard of a single person having one run right. 
Title: Re: 1.6td with 1.9 head
Post by: ORCoaster on May 12, 2018, 11:44:05 pm
I would be inclined to try the other 1.6 pump on the engine just to see if it ran.  Might not need that fancy td pump from what I hear.  Try it and let us know.  What do you have to lose but the time installing it and timing it.

Could be a solution for the short term.  And would surely point to a faulty rebuild. 
Title: Re: 1.6td with 1.9 head
Post by: Vwcaddy81 on May 13, 2018, 09:33:05 am
I'm going to swap the pumps today and if it runs I'll know for sure it's the rebuilt pump. Then I'll be dealing with hans to fix it!!
Title: Re: 1.6td with 1.9 head
Post by: libbydiesel on May 13, 2018, 11:38:40 am
From everything I have heard, their customer service with pump issues is non-existent.  I do not believe you will get any satisfaction.  Next time do a little online research before purchasing from a company.  Their bad reputation is rampant and very well-known online. 
Title: Re: 1.6td with 1.9 head
Post by: Vwcaddy81 on May 13, 2018, 02:04:57 pm
Yup I'll be calling them!! Put my na pump in set timing and it fired right up.  Not happy
Title: Re: 1.6td with 1.9 head
Post by: Vwcaddy81 on May 13, 2018, 02:19:09 pm
Where can I send this pump out to to have it fixed?? How much is it going to cost me?

Can i run this na pump in the meantime.  I have to have it about 1/2 throttle for it to kinda idle. Have to adjust it.  What's everyone's thoughts?

Engine sounds great tho. Did something right rebuilding it
Title: Re: 1.6td with 1.9 head
Post by: Ian0391 on May 13, 2018, 02:23:45 pm
I don't know what your power goals are but for not much more than your average rebuild cost you can send it to Giles and know your getting the best possible pump tuned exactly to your setup and power/fuel economy goals.

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Title: Re: 1.6td with 1.9 head
Post by: Vwcaddy81 on May 13, 2018, 09:16:19 pm
I want as much power as I can get as a daily as I can and it not blow up. 

The clutch dont work now. I have a 020301107c that was in my pickup. And the turbo engine came with a 020301107h trans.   Guess I'm going to have to switch that over and hope it works
Title: Re: 1.6td with 1.9 head
Post by: Vwcaddy81 on May 14, 2018, 10:24:05 pm
My pump is in the mail back to hans! Will keep you posted how that goes. And trans is fixed the plate was cracked that the rod hits.

Is it safe to run my pickup with the na IP and stock boost. Till I get money back and money to send my turbo pump out to giles??
Title: Re: 1.6td with 1.9 head
Post by: ORCoaster on May 14, 2018, 11:35:25 pm
If you have to have the throttle lever about half way pulled to get it to idle then just mark the current location with some scratches or a good permanent pen and reset the lever to the counter clockwise direction.  See if that helps you gain some RPMs. 


But even before doing that how about a twist of the old fuel screw on the back of the IP.  Twist it in a turn and does it bump up the idle?  If so pull the throttle and see if you gained some top RPM.  Might need to do it more than 2 times to get any power without getting black smoke belching out the tail pipe.
Title: Re: 1.6td with 1.9 head
Post by: Vwcaddy81 on May 15, 2018, 07:36:28 am
Sorry. Yes I got it to idle. Idle all the way down fuel in about 1.5 turns. It dont pour black smoke just a little when you bump the throttle.   

It does white smoke though at idle. I dont know it it's just cause the rings and stuff not seated yet or what.  The I plugged the oil drain on the aaz head. That's all I needed right?? It's a cy 1.6 block.
Title: Re: 1.6td with 1.9 head
Post by: Dakotakid on May 15, 2018, 01:12:05 pm
Of course, I have no idea if this engine was assembled properly or not. But, the longer you piddle around idling it you run the very real risk that the rings (if even installed properly) will glaze up the cylinder walls and delay seating or never seat.

Additionally, the rings will attempt to align the gaps due to a non-load running situation.

The idea is to properly assemble an engine with good parts, fire it up just long enough to determine leaks or not, then take off with it to load up the rings which introduces them to the cylinder walls. That (hopefully) anchors the rings in their position on the wall.

The time to ask about how to modify the aaz head to work on this block was like 6 months ago. It's like enjoying going to the bathroom....only to find that you failed to leave your work desk.

Yes, run the standard pump...it is fine. If you have these big ideas about making good power, a standard 190 mm clutch plate is NOT going to go far. 
Title: Re: 1.6td with 1.9 head
Post by: Vwcaddy81 on May 15, 2018, 09:05:32 pm
Yes I know all this. And yes it was put together right. I'm a diesel mechanic on both land and sea. This is just my first vw diesel. I'm a noobie to this world. And it only ran for maybe 5mins off and on. Hasn't even got up to temp yet. So I'm not worried about glazing. 

As far as the aaz head. The more I read and search the more I think it's just a hydro 1.6 head on a mechanical block. Which I had to plug the extra oil drain.

I got the whole 85 jetta for $250. Car was junk and I pulled everything that I could that was good off. I know that the head was replaced so to the fact that someone plugged the oil drain with a brass plug and then filled the hole with RTV.  And the pistons had the Mark's of saying hi to the valves.   
Title: Re: 1.6td with 1.9 head
Post by: Vwcaddy81 on May 15, 2018, 09:12:04 pm
My main thing now is running my na pump with the turbo.

If I'm going to spend $800 on a pump it's going to be for my duramax so it will be over 550rwhp not this 1.6 that mit hit 100hp. I love hp but I do it backwards. It's got to have legs to hold the power or that's all you do is find the weak links.

As far as the clutch I havent lead enough to know what i need or have to find to do that swap yet.  And I'm glad and thankful for all the info you all have giving me!!!
Title: Re: 1.6td with 1.9 head
Post by: ORCoaster on May 16, 2018, 12:48:03 am
Yes, run the standard pump...it is fine. If you have these big ideas about making good power, a standard 190 mm clutch plate is NOT going to go far. 

I agree with this one.  Run it as it is and the sooner the better.  Sorry that first rebuilt pump failed the test. 
Title: Re: 1.6td with 1.9 head
Post by: Vwcaddy81 on May 16, 2018, 12:41:21 pm
That's that's what I'm going to do then. Run my na pump till I can make some side money and have files build me a good one. Then it will be trans and clutch upgrades
Title: Re: 1.6td with 1.9 head
Post by: Vwcaddy81 on May 23, 2018, 12:25:04 am
Well pump is coming back and I'm going to try and time it again.

But my head needs to come off . Coolant is leaking next to the oil drain hole.  Been doing alot of reading. And cant find what coolant I need to block. Pictures anyone??

  Also should I use a mechanical head gasket or a hydraulic head gasket?

Any write ups on drilling the steam holes in the block?   Thanks again
Title: Re: 1.6td with 1.9 head
Post by: fatmobile on June 01, 2018, 04:21:53 pm
Felpro makes a gasket that blocks off the hydro hole.
 You still need to plug the hole in the mechanical block,.. if that's what you have
Title: Re: 1.6td with 1.9 head
Post by: Vwcaddy81 on June 04, 2018, 08:23:18 pm
I have a cy mechanic block 1.6td. They head is a hydro head.  I blocked the oil drain in the head. But have read something about a coolant passage that needs to be blocked too.  I have both mech and hydro head gaskets.   

Also the engine is running hot on the dash gauge. It's not losing coolant now. And I think the IP timing is off. Do to the fact that the cold start dont do a dam thing. I set it to 1.10mm and then move the pump as much as I could toward the head to make it run better. 


Any and all help is greatful!!!
Title: Re: 1.6td with 1.9 head
Post by: ORCoaster on June 04, 2018, 11:01:16 pm
VwCaddy81,

Also the engine is running hot on the dash gauge. It's not losing coolant now. And I think the IP timing is off. Do to the fact that the cold start dont do a dam thing. I set it to 1.10mm and then move the pump as much as I could toward the head to make it run better.

I think you have a couple of conflicts here.  #1   Heat, hot on the dash gauge.  Believe it for now, why?  Because if you set the timing at 1.10 that is a little bit advanced for the little diesels.  1.05 mm is recommended for performance.  Now that you set it at 1.10 you also pushed the IP towards the engine.  If you did that after the 1.10 set you just advanced the timing even further.  That might be a good reason why you are seeing the heat on the dash gauge. 
The fact that the cold start isn't doing a darn thing might be due to the set screw on the cable needs to be adjusted.  Getting back there is tough but you can get a nut driver on the head and loosen it up and then push the lever itself along the cable a bit then retighten the screw.  Basically you are taking the slack out of the system doing all that.


Title: Re: 1.6td with 1.9 head
Post by: Vwcaddy81 on June 06, 2018, 02:37:06 pm
The cold start is moving the lever on the IP like it should. 

IP timing to 1.10 is the only way it will run!!! And that's what the guy that rebuilt my pump told me to set it to.   

I'm going to move to one more time this weekend and then just drive it till it wont start or blows up. No more $$$$ are going into that engine.
Title: Re: 1.6td with 1.9 head
Post by: Vwcaddy81 on June 06, 2018, 06:19:17 pm
Timing is set at 1.30mm

Fuel screw out to much to be happy??
Title: Re: 1.6td with 1.9 head
Post by: ORCoaster on June 06, 2018, 11:51:57 pm
Happy could be "Rolling Coal"  But your mileage will suffer and those behind you will cuss your tailpipe. 
Title: Re: 1.6td with 1.9 head
Post by: Vwcaddy81 on June 07, 2018, 07:09:58 am
Well I jumped a tooth on the ip to towards the grill. Started right up but sounded like a big block so loosened the pump and retarded it. She is running alot smoother!!!

My temp gauge is now about half. 🤨  next thing is boost will only get to 16psi.  And then clutch