Recent Posts

1

IDI Engine / Re: Please help me get my JX 1.6TD running!

« Last post by ghostrider2 on Today at 11:46:10 am »

Thanks for all the tips y’all. In the meantime I had a shorted aux water pump cause a few wires to burn and so I had to spend some time rewiring my harness.   

But now that that’s done and a new pump is installed I advancing the timing to around 1.1mm and cleared the fuel lines of air. She starts and runs (I also ran a can of diesel purge through)! 🤩 The issue now seems to be that she’s only running on three cylinders (1, 2 & 3). 😣

Here is a video of the engine at idle and with a bit of gas. You can hear the angry tapping: https://share.icloud.com/photos/0cevD_-jF2FnmQGLgc_J9Y_QQ

Then here’s one of me checking the injectors and you can see there’s little reaction when I loosen injector number 4: https://share.icloud.com/photos/0ec8jX9MFZYJgiMPiahyXEBDg

Could the timing be advanced too far now? Anything else I should check before tearing apart the injector itself?

2

IDI Engine / Need help with tracking down air leak in 1.9 AAZ pump

« Last post by Buji88 on Today at 11:03:47 am »

Hey all,

Im at my wits end with my injection pump lol!

Likely its going to go to a rebuilder but Im super stubborn and like to fix things myself, so here's the story.

I have a 1.9 AAZ just did a fresh rebuild on the engine and been using the pump I got with the engine. Its been great up until the last few weeks.
 
I have modified the pump (keep in mind it was running great before this) with governor mod, 1.6 TD top for simpler throttle controls and better boost.

After the rebuild I did struggle with some leaks and I ended up replacing the main shaft seal, the cold start 0-rings, head seal, cover seal, throttle shaft seal. And it was fine up until this last part.

The cold start lever started leaking a river of fuel out of it. I took it off and replaced the cover with a TDI one since that's what I had, couldn't get it to run, and I realized why (TDI cover doesn't support the end of the timing piston so it basically had no timing. Fixed that and got it running. I also changed the seals on the pressure regulator (10MM plug next to fuel inlet)

This is where it's all gone sideways. I can get the engine running, but it has no power what so ever (Im doing a swap into a Suzuki Sidekick) at idle if I let out the clutch it just stalls (before it was able to get it moving). It starts fine, idles fine, revs fine but has no power whatsoever. Timing is sitting at 1.05MM. I'm getting air bubbles in the return line while it's running. I cant see any fuel leaks externally, and it always acts like the pump needs to be reprimed (lots of cranking to get it going). When it runs, it's a bit smokey grey, which I think is timing, but when you rev, it goes black. Increasing the fuel screw slightly (1/4 turn) made it easier to start but no additional power.

I haven't touched any of the seals inside the cover except for the main cover seal and throttle shaft seal. Is there anywhere it could be drawing air but not leaking fuel? With the air bubbles, it's gotta be drawing air in, but no idea at all where that might be. Or is this one of those things where you need to just change them all?

3

Troubleshooting / Re: 1981 Vanagon Diesel Surging idle

« Last post by fatmobile on May 27, 2024, 11:52:15 pm »

 I've had the RPMs hang and rise when the max fuel screw is in too far.
 I think most commonly it was caused by a pissing injector.
Fuel doesn't burn well and remains until the next time around, where it's added to the next squirt.
Lots of white smoke?

 And I'm going to mention that sometimes the pump can be put on 180 degrees out.
Not sure how, but others,.. and I have done it, long ago.

Maybe air in the fuel, do you have clear lines to and from the pump?

4

Troubleshooting / Re: 1981 Vanagon Diesel Surging idle

« Last post by ORCoaster on May 27, 2024, 10:22:32 pm »

That almost sounds like it is getting oil in the intake somewhere and that is acting like additional fuel causing the RPMs to climb.  I would look into the hoses coming off the top of the valve cover and maybe any from the block itself. 

That is my only thought at this time.  Brain barely on idle tonight.

5

Troubleshooting / 1981 Vanagon Diesel Surging idle

« Last post by Yoyota on May 27, 2024, 05:04:57 pm »

I have a problem with my 1981 Vanagon Diesel.
I put a new fuel pump in.
It starts Right up now but after about a minute the RPM's accelerate and you have to turn it off.
One you do, it resets. You can start it up again and does it all over again.
Any solutions, suggestions or Thoughts?
 

6

Parts for Sale/Wanted / Re: IDI turbo to exhaust manifold bolts

« Last post by oblique on May 26, 2024, 08:46:12 pm »

I have a mid-90s  AAZ motor that I bought aftermarket in about '01. The turbo attaches to the exhaust manifold with four 8mm -12 point bolts, two that are 27mm long and two that are somewhat longer. I've lost one of the 27mm bolts. Anyone have a spare or know of a supplier for these things? I'm thinking they're kinda unique.

There are 2 version of these bolts that I know of, both are 45mm long and both use 12mm 12point heads. The k03 AAZ's used 3-8mm bolts and the k14 flanges had 4-10mm bolts. The 1.6TD's were same as the k14.

I have some extras, let me know if you need.

7

mTDI Mechanical TDI Conversions / Re: mTDI / TDI-M Injection Pump FAQ

« Last post by rotaecho on May 25, 2024, 11:21:22 am »

Sorry, if it was answered here, but I didn't see it.

Has anyone installed a LT 2.8 VE IP (0460424138) on an ALH? I believe I read the snout is smaller on the LT2.8 vs the ALH, so curious how people dealt with this issue?

I know I can use the AHU sprocket on 2.8 LT IP, but the IP mounting portion has me lost.

Thanks!

8

IDI Engine / Re: Please help me get my JX 1.6TD running!

« Last post by RabbitJockey on May 22, 2024, 11:53:43 am »

there should always be fuel flowing through the return, the pump needs that flow to cool itself.

9

IDI Engine / Re: Please help me get my JX 1.6TD running!

« Last post by fatmobile on May 22, 2024, 08:18:24 am »

 There should be fuel returning even at idle.
 There is a restrictor in the OUT bolt that can get clogged.
 In fact the hole in that bolt is so small you might have a hard time finding it.
There is a screen inside the bolt that is supposed to keep that hole from plugging but it doesn't always work.
 You should try backflushing it.
 Or vacuum from the end of the bolt, or both.
 
 I still think your problem is retarded timing but no flow from your pump will be your next problem once timing is right.

10

IDI Engine / Re: 1.9 diesel parts book

« Last post by cdsx on May 22, 2024, 05:04:06 am »

I checked them out and they do have an extensive parts catalogue, certainly, but that's no replacement for an actual parts book. That shows every individual part, its' part number, and different applications. When the workshop manual is vague, lacking illustration, or just plain glosses over something (Are you listening, Haynes?), the exploded view in the parts book can clear up a lot of confusion. Just check out a couple of pages of a Volvo 240 parts book and you'll see what I mean. (I would have supplied an illustration to sell my point, but for some reason, this forum won't let me post an image.)