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Engine Specific Info and Questions => IDI Engine => Topic started by: Zulfiqar on June 10, 2009, 02:02:47 am

Title: starting problems
Post by: Zulfiqar on June 10, 2009, 02:02:47 am: Hi

I was rebuilding a 1.6 NA motor - and then had a little incident in which I couldnt complete it myself, my friend called in a mechanic fitter to assemble the engine - it seems that he has assembled it correctly with the timing ok and all - but when we try to start it - unburnt diesel is pumping out of the blow pipe on the valve cover - any ideas on what this could be - first it was trying to catch but now the engine is too heavy to turn over - let alone start..

the motor has new rings - new valves, guides, and everything - never had a prob like this after a rebuild
Title: Re: starting problems
Post by: Golf/Jetta on June 10, 2009, 02:53:22 am: heavy to turn over... by hand or starter?
Title: Re: starting problems
Post by: Zulfiqar on June 10, 2009, 03:18:39 am: by starter and hand both

what is puzzling is that the blowby smells of unburnt diesel - and Im getting no smoke at the tailpipe - just puffs of air pressure
Title: Re: starting problems
Post by: arb on June 10, 2009, 04:56:27 am: How are you turning it over by hand ? With a socket and rench on the crank pulley ? How many ft-lb does it take? Until you get all the injectors primed, its not going to want to run and you'll get unburned fuel. Very strange its in the valve cover.
Title: Re: starting problems
Post by: Zulfiqar on June 10, 2009, 06:09:34 am: by heavy you can say its normal for a tight diesel - like you are trying to spin a good diesel with a 19mm combination wrench on the crank pulley.

Ive retarded the pump timing a bit as it was not put on by a dial gauge, its not puffing out now - just heavy on the starter - my gauge got nicked when I gave it to a machinist for making a copy of my adapter..
Title: Re: starting problems
Post by: arb on June 10, 2009, 09:34:50 am: Quote from: Zulfiqar on June 10, 2009, 06:09:34 am
by heavy you can say its normal for a tight diesel - like you are trying to spin a good diesel with a 19mm combination wrench on the crank pulley.

Ive retarded the pump timing a bit as it was not put on by a dial gauge, its not puffing out now - just heavy on the starter - my gauge got nicked when I gave it to a machinist for making a copy of my adapter..

I hope its not the same machinist who put your engine together for you ;-)
Title: Re: starting problems
Post by: Zulfiqar on June 10, 2009, 10:45:36 am: that machinist has closed business for reasons I dont know - I made myself another adapter from the little bench lathe I have.

Anyway - I retarded the pump timing about 1 pencil line - and it does start now after towing, it gives no smoke at all no black, no white, no nothing, the blow pipe is chuffing out light pulses of air - BUT its running on only 3 cylinders the 4th injection nozzle is not working...

>:( I cant work on it at the moment and Im starting to hate it
Title: Re: starting problems
Post by: Golf/Jetta on June 10, 2009, 11:32:36 am: i wonder if the cam and crank where over tightend
Title: Re: starting problems
Post by: Zulfiqar on June 12, 2009, 12:46:21 pm: a little better development - the 4th nozzle was not working proper - serviced it and is spraying nice now, all that comes to mind now is to remove cam and take out lifters - empty them and install them back - because its not able to idle properly
Title: Re: starting problems
Post by: rabbitman on June 12, 2009, 02:17:14 pm: Could the little return line off the fourth injector be plugged into the vacuum pump? I've heard of it being done, check the oil.