trying to revive an old 1.6

[Smoker]

No white smoke. I pulled the belt and tried to flush the pump as per air cooled's advice. It won't even pull the atf out of the bottle. I'm about to head out on a road trip to pick up an alh Beetle, I'll let the pump sit with atf in it for a day and see if anything loosens up.

[RabbitJockey]

the lubromoly diesel purge is the best stuff to let soak in the pump.  i had this same issue though with an aaz pump that had sat dry for a long time, i just bought a mr gasket diesel fuel pump and tucked it behind the passenger strut tower, its only 50 bucks and it will save you lots of time getting it started, and also in the future.  I got my pump at advance auto, looks like it's 60 now, its available else where too.  i know a few people running them including someone with a built tdi running a gt2052 turbo.  the best part is you can just run the power off the fuel stop solenoid, so the install is super easy.  i'm going to run one on all my diesels in the future.


http://shop.advanceautoparts.com/p/mr.-gasket-electric-diesel-fuel-transfer-pump-12d/6340003-P?cm_mmc=ACQ-_-Google-_-Enhanced-_-Dynamic&jadid=61601342245&jap=1t2&jkId=gpt:pt_134962&js=1&jsid=34339&jt=1&jr=http://shop.advanceautoparts.com/p/mr.-gasket-electric-diesel-fuel-transfer-pump-12d/6340003-P%3Fcm_mmc%3DACQ-_-Google-_-Enhanced-_-Dynamic#utm_source=acq&utm_medium=google&utm_campaign=enhanced&utm_content=dynamic


and 320psi isn't ideal but you should have a runner at that compression level.

[ORCoaster]

RabbitJockey,   ONLY 50 bucks???   Anytime someone calls themselves a cheap B.  You know he isn't in the mood or wallet frame of mind on that advice. 

But I liked it.  The suggestion to wire to solenoid was nice touch for simplicity sake. 

[vanbcguy]

Worth mentioning that the solenoid wire isn't fused on a lot of the earlier cars.  I know it is on the Mk3 (it uses the 'Engine Management' position in the fusebox) but not sure about the Mk2 and Mk1...  So if you're running power for a lift pump from there, BE CAREFUL and add a fuse.

[Smoker]

Update: attempt #2 at flushing the pump with atf... It isn't putting anything through the delivery valves, but it is sucking atf from the bottle and sending it out the return. What does this mean??

[air-cooled or diesel]

add lubromoloy,mix and keep on running stuff thru, let sit, and do again, pump is stuck, but its starting to work, the question is can you get it where it can run again or you have to it breakdown.

[air-cooled or diesel]

do you have return going back to bottle? you can also possibly hook something up, get line that fits the pump squirters clamp, run all 4 lines back to bottle and return too, now you can keep on running pump this way and possibly wont lose the flush. continuous flush

[ORCoaster]

Smoker,  It sounds to me that you have the primary part of the pump working since it will pull fluid in and pump it out.  But what isn't working is the secondary part of the pump that compresses the little bit of fluid as the shaft rotates and rides up and down on the cam plate.  It might be a stuck spill collar or plugged holes in the shaft itself.  Just keep soaking it as suggested and hook up some hose to the back end to collect the spray that comes out there too.  No need to make this a messy job. 

[air-cooled or diesel]

prob shouldnt recycle fuel out of squirters at first; after they 'fire' a good amount, try to recycle, fi line may work with clamps. can run return from pump return. i like to use a filter , like a bug filter use to be a buck, now its over $1.50. prob shouldnt use a filter with atf though would be too thick.

[burn_your_money]

You can take the delivery valves apart and see if they are stuck closed. Just be careful not to drop the little washers out of them. Parts inside the delivery valve holders (14mm) starting at the timing belt end and moving to the drivers side
1) copper washer
2) delivery valve (2 pieces)
3) spring
4) washer

You can remove the delivery valves completely and try turning it over to see if it squirts fuel. Don't mix up the parts but they can go back in any hole.

When the collar gets stuck it's in the starting fuel position which is maximum fuel (even more than full throttle) so I'm thinking you likely have an issue with the delivery valves. If they are stuck closed you aren't going to be able to get your diesel purge mix up to them to loosen them. You can reuse the washers, although technically you aren't suppose to.

If you moved the throttle (which you likely did) the control collar could get stuck in a position other than starting fuel which could make getting fuel flowing through it slower/impossible.

[ORCoaster]

BYM,   Moving the collar off start position was what I was thinking.  There could have been that film coat on the shaft and moving the lever pushed it back from start location and now it is jammed back a bit exposing the spill hole.  And It won't come back on its own.  I wonder if popping the top to get down in there is an option rather than dismantle the pump end?

Cleaning the delivery valves is a good thing to do as well,  Just eliminates it from the potential cast of characters that can make fuel deliver a problem. 

[burn_your_money]

You should be able to take the top off to try and move the collar. Obviously much care would be needed.

Spinning the pump at high RPM might push it back as well but that's not too likely I'd say.

If it's that stuck, it's going to need seals so I'd just tear the whole thing down and remove some variables.

[Smoker]

I'm 99% sure I never moved the accelerator.

I did have a thought earlier today... maybe I should power the shutoff solenoid before I try to get anything out of the delivery valves?  Lol.  Now it spits some atf while spinning it with the air ratchet, but not much...

[Smoker]

My Dasher's old pump is sitting on my shelf.  It ran great, but wouldn't hold its prime.  One of these days, I need to dig into one of these pumps so I can understand how they work.  Maybe today is the day...

[Smoker]

I'm having a hard time wrapping my head around what should be happening when I'm flushing the pump. Or more specifically, how much atf I should see. I'm used to seeing diesel fuel hitting the hood when injector lines are cracked to bleed air, but it isn't putting much atf out at all. Thoughts?