Horrible Mileage...STILL...after alot of work/troubleshooting

[Doakster]

Don't sweat looking for marks on sprockets... often not there, and not needed:

Basic belt timing is set by:

- cam sprocket loose
- cam locked at TDC with cam lock plate
- pump sprocket locked at TDC with pump lock pin
- crankshaft at TDC mark on flywheel
- cam sprocket tightened

Actual pump timing is set to 0.95mm using a dial indicator as per the service manual or here:

http://vincewaldon.com/index.php?option=com_content&task=view&id=24&Itemid=28

Yeah that would be fine but if it's like my pulley it's got two holes that the pin fit's in, mine has the mark though.

I guess you could point the keyway the right direction but I forgot what that is .

I think my pulley only has one hole for the lock pin, which will work toward my benefit, i'll have to look when I pop the timing cover off. Also I'll take note of where the key way is on my eco pump before I pull it off. I'll make sure to mark the pulley and or key way position before it comes apart.

You guys using any special puller to get the pulley off? Seems like it should come off being that the pump shaft if tapered.

[dash cunning]

i use a gear puller and some tapping with a hammer. it's keyed so it won't come right off.

[54321chris]

Probably a bad idea and you'll have plenty of people tell you not to, but I have used a screwdriver behind the pulley to wedge it off.  The only puller I have is the one for the TDI camshaft, and it won't work, so I got creative. 

[87octane]

In Cali, the petroleum refiners are required to change smog gasoline formulations from summer to winter, and winter gasoline makes horrible power and mileage goes to sh!t. Late model, ragged edge, fuel injection tunes have to be completely rescanned and spark and fuel tables modified for winter crap gas in you high compression late model hot rods. (My LS2 at 11:1 AFR freaks out when they switch the gas)

Do the diesel refiners in anybody's area have to change to a "winter diesel" formulation for air quality reasons, and if so, could that have massacred somebody's mileage overnight, regardless of tuning/repair/etc.

Is Cali #2 LS pump diesel considered worse than 49 state or CANA #2??

[Doakster]

In Cali, the petroleum refiners are required to change smog gasoline formulations from summer to winter, and winter gasoline makes horrible power and mileage goes to sh!t. Late model, ragged edge, fuel injection tunes have to be completely rescanned and spark and fuel tables modified for winter crap gas in you high compression late model hot rods. (My LS2 at 11:1 AFR freaks out when they switch the gas)

Do the diesel refiners in anybody's area have to change to a "winter diesel" formulation for air quality reasons, and if so, could that have massacred somebody's mileage overnight, regardless of tuning/repair/etc.

Is Cali #2 LS pump diesel considered worse than 49 state or CANA #2??

in my situation, it's not the winter/summer diesel blend affecting my mileage, I have run the car both summer and winter with poor mileage.

[Doakster]

i use a gear puller and some tapping with a hammer. it's keyed so it won't come right off.

Shoot what was I thinking. I have a 2 jaw 3 ton puller that should work, and if that doesn't I have a 3 jaw 8 ton puller that will  pop it right off.

I've done the chisel behind the cam pulley before, and it worked slick.

[calebessent]

Does anybody want to disclose what that pump cost?

Being naturally-aspirated is really killing me. I'd love to go turbo.

[Rabbit on Roids]

Does anybody want to disclose what that pump cost?

Being naturally-aspirated is really killing me. I'd love to go turbo.

then bolt a turbo on your engine and turn your fuel up a little bit. you dont NEED a turbo pump to run a turbo. you can do it just fine with an n/a pump. if you arent looking for a complete performance build, just use the stock n/a pump, you already have it bolted on the engine, and im assuming it runs pretty good?

[Quantum TD]

So, how's the fuel economy after the rebuilt pump?

[calebessent]

then bolt a turbo on your engine and turn your fuel up a little bit. you dont NEED a turbo pump to run a turbo. you can do it just fine with an n/a pump. if you arent looking for a complete performance build, just use the stock n/a pump, you already have it bolted on the engine, and im assuming it runs pretty good?

I'm not trying to thread-jack, I just wanted to say thanks for the encouragement.


Back on topic... yeah, what's the fuel mileage like, now?

[Doakster]

Working on it this weekend, been working on getting my gauges in today. I've haven't had much time to work on it.

Plan on starting the pump install tomorrow, I'll report back.

With my new injectors and my eco pump, I can pull 10 psi of boost on a heavy load, sound about right?

On another note, my turn signals don't work when my head lights are on, WTF?

[Quantum TD]

Working on it this weekend, been working on getting my gauges in today. I've haven't had much time to work on it.

Plan on starting the pump install tomorrow, I'll report back.

With my new injectors and my eco pump, I can pull 10 psi of boost on a heavy load, sound about right?

On another note, my turn signals don't work when my head lights are on, WTF?

Those late Jettas had a lot of problems with the headlight switches. I'd start there and move to other things. Also check your grounds in the engine bay, and the headlight bulbs themselves. I've had issues on headlights where one light would go high beam, and the other low. Then they'd switch when when I hit the high beam switch. Turned out to be mis-matched bulb brands. New bulbs fixed it.

[Doakster]

I think i found my turn signal issue, silly switched out to amber bulbs when i swapped in clear turn signals just recently, i didn't by dual filament bulbs, have to go get the right bulbs.

I'm in the process of the pump install right now, and am about to time the pump, going smooth so far.

[Doakster]

Success!! Car is running and warming up on the new pump.

I think i need to adjust the idle speed, I'm going to wait until it comes up to temp and check RPM at the IP pulley with my laser tach, I'll be going off the bentley specs and divide by 2 for the IP pulley speed

[Doakster]

Pump install is complete. Over all is went very well. Not too many issues, other than my return line from the out bolt blowing off, had to replace the cheap clear tubing I had on there with some black rubber line, and it took awhile for all the air to get out of the system. 


Out with the old pump, it looks pretty ragged.



New pump installed with, new lines as well, set the timing to .95mm per Giles recommendation.



I also installed my votex console, with my gauges and new radio, the radio isn't wired up so I have to come back and do that later, the stock radio hole will get a blank pocket/cubby.





This coming week i have to get these rims mounted on some snow tires and I'll be ready for winter mode. I also have to get a new battery, the battery is on it's way out and doesn't hold a charge all that well.




Overall I am pleased with the new pump, throttle response is better, the car pulls a lot harder, it feels kind of like driving a TDI that has a few less ponies.

I also pulled 15lbs of boost in 3rd and 4th before I got to 1200 degrees EGT and backed out of it. The EGTs really stay up there on 5th gear long hill pulls, maybe an intercooler will be my next summer project, i can't imagine what the EGTs would be with a stock exhaust, scary.

Many thanks to Giles for the new pump and injectors, it took a while and some headaches but looks like i have a strong pump and good injectors (that don't leak  )

I won't be able to do a mileage run until later this week, so I'll have to wait to see what I come up with for numbers.

Overall i'm pleased, the car has been sitting for the last few months and it feels good to have it running well again.