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General Information => Troubleshooting => Topic started by: Kudagra on July 20, 2013, 03:57:31 pm
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So i have an 85 Jetta mech head 1.6td with a Giles pump. Feeding it is a 93 GM 6.5 td lift pump. I cannot set the high RPMs any higher then 2900rpm. When bleeding the air.from the injectors the fast idle cam linkage fell apart (I never touched it) and the sporting the spring inside fell off. I put it all back on with the pump installed (not a fun task) then it would not start till i put the throttle at about 25-30%. I removed the pump, took off the top cover and reattached the spring. Re assembled the pump, installed and bled the air. Now the engine starts and idles but I all can't get more then 2900rpm. Its like its hitting the governor
Any idea what under the cover might not be right and causing this problem?i have clear hoses on the inlet and outlet of the pump. I have no air in either.
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You are probably 1 or 2 splines off on the throttle shaft.
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Not sure. It did that before I took it apart. That would mean Giles put it together wrong, which I find hard to believe. It reaches 2800 when the throttle is at about 50%. Then it just does nothing else any more then that.
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Try running it off a jerry can and see what that does. Also, any restrictions on the air intake or exhaust?
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Not even an air filter on the turbo. Im going to put a fuel pressure gauge on the inlet next week. I'm just wondering if there could be anything that came loose inside when that linkage came apart our when I put it back together
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Even without that idle lever hooked up you should still be able to rev a Giles pump further than your engine could handle.
Did you have to fiddle with the max fuel screw?
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Nope. Didn't fumble with any set points. It fires right up. It revvs quickly..but it hits a wall at 2800-2900. Just fyi I'm using a photo tach and 2 reflectors on the injection pump pulley.
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You marked the orientation of the throttle shaft to throttle arm as well?
Not sure. It did that before I took it apart. That would mean Giles put it together wrong, which I find hard to believe.
He is only human, it is possible. You should take a good picture and scribe lines where it is set now and play with the settings. There isn't much else that could give you your issues.
Is it a TD pump?? I have an idea.. if the limiting pin in the lid is stuck and not allowing the pin to push out against the boost pin when it moves down under boost pressure.. you should effectively be left with about as much fueling as you have. It is definitely worth a shot my friend.
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FWIW, this is similar to what happened when i got some wet fuel.
+1 on the jerry can/purge can.
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(http://i.imgur.com/q23DTk7.jpg)
I take pictures. This is before anything was disassembled.
Sorry...resized.
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I can tell you right away, the way you have it set up right now is all sorts of effed-up. AKA wrong. lol.
Set that to the middle line and readjust the max screw and the idle until you get it runnin right.
You are going to have to back the max fuel screw WAY OUT. I suggest like the last two threads and start from there, after you readjust to the middle line on that spline. Try and crank, no go? Turn it in a full turn etc. etc. Until you get it to idle or runaway a bit and then back it out. From there it just needs the idle set and you are golden.
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It is either that, or the idle needs bottomed out and the fuel screw turned way up. I have run them this way before, and you get a lot of fueling.
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Ya know...that doesnt make me feel good. I never messed with any adjustments or linkage on this pump. It was never even ran since I paid $1100 5-6 years ago. I installed it and set the advance. Cranked it enough to bleed the injectors. It ran and the linkage fell apart. Now you are telling me the throttle shaft was installed wrong? Ugh. I know no one is perfect but damn. I'm just going to figure it out. No accusations. Giles is a good guy and I'll still recommend him over anyone else. Something silly happened here but I'm not sure what.
I'm going to reset the shaft splines (I thought it was odd the lines didn't line up) and I'll go from there.
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I spoke with Giles about mine, I suggest you do the same. He worked on my pump at a discounted rate as he said he would stand behind his work. I cannot speak for him but I would almost guarantee that he will help you out if you contact him first. I bet he would tell you to try all these suggestions first and then go from there. I think everyone is on track here, but it would be nice to know from the guy that built it.
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If you are getting a reading of 2900 off the pump pulley then you have no issue.
I wouldn't adjust anything before talking to Giles.
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but he said he had 2 dots on the pump gear so it would really be 2900
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Good point.
My second point still stands though
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I can tell you right away, the way you have it set up right now is all sorts of effed-up. AKA wrong. lol.
Set that to the middle line and readjust the max screw and the idle until you get it runnin right.
I can tell you that the throttle shaft is in the correct position based on my experience from working with Giles.
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Im also half a continent away.
Im going to check the fuel pressure and go from there.
Im just not too thrilled about a 1 month turn around time. Its not Giles...its waiting on those morons in Customs to realize I dont have 40lbs of weed in my pump (at least I dont think so but that would explain things)
So you are saying to leave the shaft alone?
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Yeah customs can really bugger things up.
I'm saying to leave all the pump settings alone, as visually they appear to be in the proper position to where Giles would set them.
I'd recommend calling Giles and going through his troubleshooting procedure. That way you have a much higher chance of success if you need to make a warranty claim. If you've fiddled with it outside of what he recommends you may be on your own, which would suck.
I'm fairly certain that the first thing Giles is going to tell you to do is to run it from another fuel source, especially when he hears that there is an extra lift pump involved.
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I bought it back in 07 (guess that is 6 years ago) I cant really expect a warranty. I did have to pull the top off because the spring for the fast idle kick up came off when the linkage fell apart.
Ill check pump internal pressure with my lift pump (I used the 93 GMC 6.5TD lift pump a few people told me Giles recommended) and all new 3/8" steel and copper lines for feed and return. Ill also check it running off an fuel can. I really want to eliminate all issues before calling. (also nice to document them here because he can see all this and what Ive done)
Really the last thing I thought is something is wrong in the pump. The ONLY thing Im not sure of is if I installed my new set of injectors in this engine or the other one. But when bleeding them they all sound the same on each cylinder when its being bled.
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The two parts of the accelerator lever are not indexed together correctly. The one on top should be rotated CW relative the other one until the little m6 bolt is at the other side of the slot and the little hole in the top one aligns with the nub in the bottom one.
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I can tell you right away, the way you have it set up right now is all sorts of effed-up. AKA wrong. lol.
Set that to the middle line and readjust the max screw and the idle until you get it runnin right.
I can tell you that the throttle shaft is in the correct position based on my experience from working with Giles.
Missed that it was a Giles pump, MY bad. I have run them this way before too.. but they are usually pretty finicky with adjustments.
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We were messing with it last night and found the internal pump pressure to only read electric lift pump pressure (8psi) even while running. It should be like 37 psi at 1000 rpm and so we think the vanes of the internal lift pump have gummed up.
Do any of you have experience with Diesel Purge?
I'll let Kudagra fill in the details cause I think it's improving the longer it runs.
Aaron
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Diesel purge is the best stuff I have ever ran in my diesel. ATF is supposed to work too.
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It could just be the pump pressure regulator is gummed up
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It could just be the pump pressure regulator is gummed up
It could either be gummed permanently up, but if it is stuck down.. the pump will easily push over 175psi no problem.