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General Information => Troubleshooting => Topic started by: gigaz2 on June 03, 2008, 01:32:48 pm

Title: IP rebuild question
Post by: gigaz2 on June 03, 2008, 01:32:48 pm

just crossed my mind..

the cam disk can be mounted 180º backwards, in this IP I set it to be in the same orientation as the woodruff key, is this the correct orientation?

Title: IP rebuild question
Post by: jimfoo on June 03, 2008, 03:30:56 pm

Good question. Mine was the opposite, but someone else said theirs was in line with the key. A little late now, but always make sure of the orientation of any parts that have more than one before you take something apart.

Title: IP rebuild question
Post by: gigaz2 on June 03, 2008, 03:40:40 pm

was searching and reading that it is supposed to be inline  :?

http://www.vwdieselparts.com/forum/viewtopic.php?t=6694&highlight=bosch+epve+stripdown

but.. if it were upside down, it wouldn't start would it?

I guess it could be only air inside the IP causing all havoc.

Title: IP rebuild question
Post by: gigaz2 on June 04, 2008, 03:32:49 am

thanks for the answers, I got this thing to idle decently, accelerates perfectly but as soon as I demand a bit of power, it stalls.
grey smoke coming from the tailpipe, and some from the crankcase ventilation :(

I'll get a DTI today, but what should be my timing?

1.6td pump, aaz camplate, 10mm plunger, 1.6td delivery valves, 1.6td stock injectors

this car was running fine two days ago when I started to mess with it.
I triple checked the basic timing, its spot on, cam locked, IP locked, I get TDC mark every time.

how can I be sure there isn't air in the IP?

Title: IP rebuild question
Post by: Op-Ivy on June 04, 2008, 08:40:45 am

Quote from: "gigaz2"

how can I be sure there isn't air in the IP?

Make sure fuel line connections are tight.

Fill the IP with clean diesel from the "out" bolt.

Title: IP rebuild question
Post by: jimfoo on June 04, 2008, 10:30:38 am

One thing I have wondered is that with a different plunger size, won't that affect timing as the pump builds pressure sooner due to moving more fuel for the same lift?

Title: IP rebuild question
Post by: gigaz2 on June 04, 2008, 12:31:31 pm

my super good timing methods (ear) already compensate for that.

I'm waiting for a DTI, should be here by now

Title: IP rebuild question
Post by: gigaz2 on July 16, 2008, 01:16:28 pm

it RUNS!!!! :D

now I have to fix my camera so I can put it on youtube.

I had the pump 180º out of whack, symptoms: only started with the pump timed to a very specific place, and after a long cranking session with full throttle applied.
it had white unburned smoke coming from the exhaust and no power whatsoever :cry:

took the belt off, turned the pump to the OTHER indexing hole, then double checked, tried to start it and it started at the first crank   :shock: but with a LOT of white/grey smoke.

I thought: its a tooth off.

it was, now it starts on the first crank, even without using the glowplugs (30ºc outside, its a cool sunset ;) ) makes absolutely no smoke at idle, and the K24 spools just by crossing the 2000rpm point :twisted:  even without load!

man am I proud of this forum! I couldn't ever figured it out without you guys!!!

thank you!

Title: IP rebuild question
Post by: gigaz2 on July 17, 2008, 10:42:28 am

just went for a drive, and I really have to back off the residual fuel screw and LDA!
this has gone from a car to a weapon! when i touch the throttle it projects a cloud of thick black smoke that makes houses disappear...

the last vehicle I've seen to make so much smoke was a 90ton tank :O

I imagine the EGTs on this setting.. through the roof for sure.
it drives fine, I just have to be extra careful on the loud pedal