Crazy basterdised build first start issues, may be pump related???

[ryanp]

Hello,

Just managed to get the engine into my dad's caddy, I'll get some pics tomorrow, here is the spec so far:

1.9D 1Y N/A base engine
GTD Pump – 1.05mm timing
1.6d pump bracket and engine mount
PD130 inlet manifold with custom race pipe
Passat AFN oil cooler and pipe
Passat V6 4 motion Oil filter
TDi GT15 Turbo
TDi Oil feed pipe and housing
Oil return to sump with custom pipe (close to shaft though!!!)
Sharan FMIC with flexible silicone Pipe work (no i/c fitted yet!)
Stainless Hose clamps
Cone Filter with custom feed pipe
Golf mk4 Clutched alternator
TDi alternator bracket
New Cam belt kit
New Aux belt
New fuel filter
New Glow Plugs

Not much of the mk3 engine remains, lol

I fitted a lift pump to prime the injection pump which has stood for a long time, once i bled the air from the injectors the engine fired up but seemed to rev as though the pedal was to the floor!!! I removed the lift pump and tried again but the engine does not rev as high. Both times the throttle lever makes no difference to the engine.

Does this sound like a failed pump? without the lift pump it only slowly pulls the fuel in through the clear line i fitted, slower than my tdi anyway.

I've not put a hand primer in the line but am yet to test this although something else is the cause i'm sure!!!

any input/tests will be welcomed!!

Thanks

Ryan

[Mark(The Miser)UK]

Hello,

Just managed to get the engine into my dad's caddy, I'll get some pics tomorrow, here is the spec so far:

1.9D 1Y N/A base engine
GTD Pump – 1.05mm timing
1.6d pump bracket and engine mount
PD130 inlet manifold with custom race pipe
Passat AFN oil cooler and pipe
Passat V6 4 motion Oil filter
TDi GT15 Turbo
TDi Oil feed pipe and housing
Oil return to sump with custom pipe (close to shaft though!!!)
Sharan FMIC with flexible silicone Pipe work (no i/c fitted yet!)
Stainless Hose clamps
Cone Filter with custom feed pipe
Golf mk4 Clutched alternator
TDi alternator bracket
New Cam belt kit
New Aux belt
New fuel filter
New Glow Plugs

Not much of the mk3 engine remains, lol

I fitted a lift pump to prime the injection pump which has stood for a long time, once i bled the air from the injectors the engine fired up but seemed to rev as though the pedal was to the floor!!! I removed the lift pump and tried again but the engine does not rev as high. Both times the throttle lever makes no difference to the engine.

Does this sound like a failed pump? without the lift pump it only slowly pulls the fuel in through the clear line i fitted, slower than my tdi anyway.

I've not put a hand primer in the line but am yet to test this although something else is the cause i'm sure!!!

any input/tests will be welcomed!!

Thanks

Ryan

Are you saying it is revving out of control from start-up, and a little less fast w/o a lift pump?
Try turning your max fuel stop out a turn...

What's your injector break pressures?

[burn_your_money]

Did it rev past redline?

[ryanp]

it revs out of control as soon as it fires up but it's not revving past red line according to my ear, no tacho it does try to settle down a little then cuts out. lack of exhaust makes it sound worse really! it is less harsh without the lift pump

It's a stock 1.6gtd pump and stock 1.9d injectors, never messed with either.

I'll back the screw out and report back, any ideas in the meantime as i'm gonna pull it out of the garage once the shafts, linkage and DP are fitted!!

Thanks for the help so far!!

Ryan

[regcheeseman]

1.05 timing on a GTD pump?
I believe it shopuld be around .85

Back the fuel screw out.

[ryanp]

I'll try the screw and back the timing off, i assumed 1.05 as it's a 1.9 engine, should i try .95?

cheers

Ry

[54321chris]

My pump was doing this after it sat on a shelf a few years getting gummed up with diesel.  I don't know anything about pump internals, but my mechanic told me the pump needed a rebuild, something (?) stuck.  After a rebuild, worked great; expensive solution though. 

[Rabbit on Roids]

My pump was doing this after it sat on a shelf a few years getting gummed up with diesel.  I don't know anything about pump internals, but my mechanic told me the pump needed a rebuild, something (?) stuck.  After a rebuild, worked great; expensive solution though. 

probably coulda ran some diesel purge through it and fixed it for cheaper.

[ryanp]

moved the screw out one turn, may be a slight difference but not too sure, two turns and 1.5 turns stopped it starting!

no air in the lines at all now but i'll leave the hand priming bulb on there!

If the pump is dead i can take it to a local guy for a rebuild cheap i imagine. would be rude not to mod it whilst there! the cam belt needs to be removed to swap the weeping crank seal anyhow!

This is the setup:



The intercooler needs fitting so the flexible pipe pipe is just looped at the moment!

Another minor snag:



dont know how the downpipe will fit even though it's worked for other before, maybe swap the rod for the shorter weighted rod from a mk3? doubt that will move it at all though!

Anyone have any ideas for the never ending list of jobs!!

Cheers

Ry

[rolo]

The injectors on the 1y have  2 set pressures 130 and something higher (160??)  if you`ve got the lower ones in your timing will be wrong(er). Sounds like a pump problem though. If they are the higher ones have you still got the original pump? It possibly has a 10mm head, remove the max fuel stop and fit the lda from the gtd. Just to reiterate you should have aaz rods and pistons in there. Cheers rolo.

[Smokey Eddy]

That intake is PERFECT for my build!!! =D

[ryanp]

I think i have 10 of those intakes at the moment, i sent one to zagarus for his jetta coupe project, check his thread!

Rolo, still have all the old stuff. I'll check my pump and injectors and report back. if it's 10mm and this pump is dead that aint too bad, lol. would the lda from any bosch td pump fit as i can get a pug one easily.

Anyone else have any ideas about what i can do???

Cheers!

Ry

[regcheeseman]

gear linkage.... shorten the tie rod.

or shorten the arm.

It's normally doable with a standard linkage, if you have a decent downpipe

[ryanp]

Yeah i have a weighted rod from mk3, i'll try that.

Does the pump sound fooked then as i've no idea what to do with it!!

[ryanp]

i've taken the pump to a bosch specialist to be rebuilt. will report back next week once it is fitted.

looks like the mk3 weighted rod is way too short and knocks the 'ball' out of alignment! no way would any downpipe fit at the moment!

Rolo, the 1y pump i have has a 8mm head!!! lol

thanks

Ryan