Author Topic: 1.5 Pump problem (Read 4802 times)

71vdubturbo · « **on:** April 09, 2008, 05:02:19 pm »

Hey guys, this is my first post. I've done a lot of reading and I think that this is the best IDI forum out there.

The problem we are having is the pump isn't pumping to cylinder 2. We had all the injectors rebuilt and pop tested. I undid the injector line and barely and diesel comes out. I took the delivery valve out of the back of the pump and it still barely comes out.

The truck ran fine just a week ago. Then all of a sudden it started missing on cylinder 2. Everything on the motor is brand new except the pump.

What do you guys think? Is the pump screwed or is there a way I can take the pump apart to see what is stopping it up? Thanks.

71vdubturbo · « **Reply #1 on:** April 09, 2008, 07:40:04 pm »

http://picasaweb.google.com/vw.crazy.04/RabbitTurboDiesel

This link is to some pictures I have of the motor before it went in. Also, there are some pictures of the motor installed.

dillenger1 · « **Reply #2 on:** April 10, 2008, 05:06:12 am »

I dont see a oil drain line for your turbo?(sorry for the jack)

71vdubturbo · « **Reply #3 on:** April 10, 2008, 06:47:43 am »

It's there. We drilled a hole in the pan and brazed a pipe into it.

Baselyne · « **Reply #4 on:** April 12, 2008, 01:49:24 pm »

wow what a build there "71vdubturbo"

that's an amazing paint and I love what youve fab'd for the manifold tube and exhaust set up

71vdubturbo · « **Reply #5 on:** April 12, 2008, 02:08:23 pm »

Thanks Baselyne. I originally had the turbo on the underside of the manifold but I found out that it interfered with the driveaxle. Then I figured "hey this has a turbo on it, why not let people see it." The rest of the custom fab was out of necessity. It sounds like a mini Cummins when you stand next to it. It has a nice turbo whine.

Just an update on the pump, we sent off the original 1.6 pump to get rebuilt. We thought the 1.5 pump that is currently on it was rebuilt. Well, it's not. So here in a week we'll see how it runs with a rebuilt pump on it.

Baselyne · « **Reply #6 on:** April 13, 2008, 11:18:05 am »

Im kinda currous to find out whats going on with your pump here...

71vdubturbo · « **Reply #7 on:** April 13, 2008, 12:19:18 pm »

well when I talked with the diesel shop, they said it could be the engine or the pump. Evidently the pump is putting out fuel to all cylinders. But for some reason #2 cylinder isn't firing right. We hooked up the injector to a separate line to see if it was giving fuel. Well it was.

I've been debating whether or not the pump is actually at fault. All I can think is that the cylinder is loosing compression. All it could be is the piston rings or the valves. The shop said that if the valves were too tight in the guides, the valves could be floating, causing the piston to just barely touch the valves.

71vdubturbo · « **Reply #8 on:** April 13, 2008, 01:17:34 pm »

Thats what I thought and it's also what the shop told me. I verified that the #2 injector was pumping. We let the truck run for about a minute to let the air bleed out of the line. It was pumping fine.

The motor is completely rebuilt. I guess there could be a ring broke or misadjusted valve. Either way, the pump did need to be rebuilt.

Baselyne · « **Reply #9 on:** April 13, 2008, 01:41:50 pm »

did you replace the rings and/or valves?

71vdubturbo · « **Reply #10 on:** April 13, 2008, 01:45:41 pm »

Yea, the motor was bored 40 thousandths over with brand new pistons and rings. The bottom end was assembled by a local respected machine shop. The head was bought as a rebuilt head with new valves, guides, and seals.

71vdubturbo · « **Reply #11 on:** April 13, 2008, 01:53:13 pm »

The motor ran fine when we first got it running. It had about an hour of run time on it. Then a few days later, we went to start it again and noticed it was missing.

We know it is something with the #2 cylinder because when you crack open the injector line there is little difference in the running of the engine. All the other injectors, when cracked open, will almost stall the engine.

Also when the #2 injector is not hooked up, the engine doesn't smoke.

71vdubturbo · « **Reply #12 on:** April 16, 2008, 07:58:33 pm »

Ok, so it turns out the pump is perfect. Not a problem at all. The problem still lies within cylinder 2. So today I decided to start the process of pulling the head. I got the valve cover off and started with checking valve clearance. Everything was ok. Next I pulled the turbo and started work on the intake manifold.

To my horror, when I pulled the intake manifold from the head I noticed a piece of cloth sticking out of the #2 intake port. As I pulled it out, I noticed it was about 1 foot by 1 foot. It was jammed behind the valve, not allowing air into the cylinder. And when I say jammed I mean seriously jammed. But it wasn't stuck in the valve luckily.

I have no idea how it got in there but it did. I'm just glad I don't have to pull the head.

71vdubturbo · « **Reply #13 on:** April 19, 2008, 06:19:53 pm »

Here are some pics of the complete motor.
pic 1
pic 2
pic 3
pic 4
pic 5
pic 6
pic 7
pic 8

Here is a video of it running.
video