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Engine Specific Info and Questions => IDI Engine => Topic started by: riceatingrabbit on May 30, 2009, 09:26:42 pm
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ok...
today I finished putting my "new" 80k mile 1.6NA in my rabbit.
I timed it to .036" checked and re-checked EVERYTHING... when I went to go start it for the first time, I found that the battery was almost dead. I wasn't patient enough to wait for it to charge.. Because I only had limited cranking power, I decided not to waste it on bleeding the fuel system. after about 30 seconds of cranking, it sputtered to life! it ran like crap for the first minute or so, then it smoothed out.
It was idling too low to stay lit, so I cranked on the idle screw until I had nice ~900rpm idle..
the engine was running GREAT.. idling great, instant throttle response, smooth rpm transition... I was very happy with it!
The guy who I got the engine from said that it had been sitting for about 5 months at the warehouse, and he gave me a can of "Diesel Purge" and recommended running it threw to clear out any deposits in the pump or injectors.
Since it was running well, and I had it up to operating temp, I decided to run it threw.
the can says " connect the feed and return lines to the can, and run it at various rpms" and the guy told me to run it for about fifteen minutes..
thats what I did..
...and thats when something broke...
THE PROBLEM
I had been running it for about 5-10 minutes on the Diesel Purge. letting it idle and running the rpms up and down.. I thought, "well, lets really blow the junk out of this thing..." and I revved it high... estimate about 4-4.5k rpm... on the third or fourth high rev, it made a loud *CLICK* and then stopped INSTANTLY... it didnt sputter or run rough, it just stoped.. almost like it seized...
My first thought was that it sucked a valve or seized or something...
but, it turned over without any sort of metallic/internal engine noise...so, I decided to restart it.
*still on the diesel purge, can getting low*
it ran VERY rough, but it ran. it would not idle, it took about 1/3 throttle to keep it running. and when I gave it more throttle, it would hesitate horribly, and only rev to about 2k at WOT
Then I realized that the can was low, and it was most likely sucking air. and it may have been sucking air for a considerable time.
I decided to put it back on diesel and see if it made a difference...... and it did..
on diesel, it would idle, but still very roughly. it would also rev higher, but the throttle response is slooooow... It is also smoking gray, in all rpms..
so... this is what i am thinking.
-its obviously NOT an internal engine problem because it turns over smooth and doesn't make any bad noise..
-its not an injector(s) because whatever it is affected all the cylinders at once... almost like the fuel solenoid turned off.
that leaves the pump...
so, if my above assumptions make sense, than what could be the problem with the pump?
a few things I think might be applicable:
it was running on a small amount of fuel, and probably sucking air. Is it possible for the pump to have overheated? and if so, what would have been damaged? (note:) when I switched it back to diesel, the fuel was HOT. and the fuel line bolt was *almost* too hot to touch)
could I have an air pocket in the pump?
could it be a supply issue? maybe the lift pump inside of the pump failed?
I'm very mechanically inclined, but I have a limited amount of experience with diesel, so I am learning.. please try and analyze my situation make any sort of input....
thanks for reading my long rant..
I REALLY want this poor rabbit to be on the road....
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You may have skipped the timing belt. You shouldn't rev any engine like that with no load.... ESP if it was sitting. Check the pump and cam timing.
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hmmm... ya, i figured it was a bad thing to rev it like that..
the belt was tensioned well, and the pump it tight in its mount.. is it really possible that it slipped a tooth?
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Something may have fell into the belt, like a nut or bolt, causing it to skip a tooth.
Mine revved to 4500rpm it neutral on accident one time and nothing broke, never new it was bad.
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that may be possible, but would it have caused the engine to stop instantly? I will be checking timing and what not in the morning..
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Check the timing just to rule it out, after that I think I'd worry about the IP. Lots of fuel goes through it for cooling so it could've gotten to hot.
Make sure it has oil pressure at the head also. Hope it starts working.
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ok... i've just been out there tinkering..
the pump skipped over a tooth on the t belt.. with the cam lock in, I had good crank alignment but the pump pin wouldn't go in...
I also noticed the t-belt was a little looser than i had had it..
i took it down and timed it again...
then I timed the pump to .90 mm
I am putting it back together now..
fingers are crossed!!!