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Engine Specific Info and Questions => IDI Engine => Topic started by: ryanp on February 01, 2010, 11:41:07 am
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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
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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?
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Did it rev past redline?
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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
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1.05 timing on a GTD pump?
I believe it shopuld be around .85
Back the fuel screw out.
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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
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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.
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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.
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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:
(http://i463.photobucket.com/albums/qq352/ryan-pak/caddy/SNV81795.jpg)
The intercooler needs fitting so the flexible pipe pipe is just looped at the moment!
Another minor snag:
(http://i463.photobucket.com/albums/qq352/ryan-pak/caddy/SNV81798.jpg)
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
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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.
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That intake is PERFECT for my build!!! =D
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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
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gear linkage.... shorten the tie rod.
or shorten the arm.
It's normally doable with a standard linkage, if you have a decent downpipe ;)
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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!!
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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
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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
1Y basically has a eco diesel injection pump on it doesnt it?
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My "Autodata" tells me there is a10mm version
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gear linkage.... shorten the tie rod.
or shorten the arm.
It's normally doable with a standard linkage, if you have a decent downpipe ;)
Reg,
Tried a shorter weighted rod, wont even work with it! shortening the arm will increase the throw?
I cant see how a downpipe would fit the standard linkage at all, maybe an Up-Pipe would! lol
rolo, i'll go look at some other 1y's. Need to install my copy of Autodata too!
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any help with the linkage? will be fitting the intercooler tomorrow and sending it off to my mate for the end caps welding on!
ry
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linkage issue resolved! how it was:
(http://i463.photobucket.com/albums/qq352/ryan-pak/caddy/SNV81798.jpg)
with the downpipe on it almost caught in neutral!
made a short shift without the need to weld:
(http://i463.photobucket.com/albums/qq352/ryan-pak/caddy/SNV81800.jpg)
Just warmed it up and bent it to suit, one hole and it's done. reduced throw by about 30-40%.
I made this too to swing the arm out of the way a bit more:
(http://i463.photobucket.com/albums/qq352/ryan-pak/caddy/SNV81802.jpg)
its a mk3 weighted rod made to be 25mm shorter than the stock mk1 item
to be on the safe side i've made a brass bush for the part nearest the DP in case it melts the stock plastic one, as well as a better bush made from nylon for the other end as the new one was sloppy!
(http://i463.photobucket.com/albums/qq352/ryan-pak/caddy/SNV81827.jpg)
(http://i463.photobucket.com/albums/qq352/ryan-pak/caddy/SNV81832.jpg)
This is with the linkage in second gear, it would nearly catch in neutral before!
(http://i463.photobucket.com/albums/qq352/ryan-pak/caddy/SNV81835.jpg)
It fits perfectly! I can now get all 5 gears and love the way the shift feels!!
The rebuilt pump also came back, the guy said it was caked in crud inside from old diesel ect and it was a suprise it did not damage the pump when starting the engine!
I refitted it, timed up to .95 advance this time, and after a minute or two bleeding the HP side it fired right up! tickover needed adjusting down and that was it!
took it for a little drive up and down, its loud! and the poly mounts i fitted are coming off today! i need new fillings in my teeth! I also have a slight oil leak from the sump and the filter housing, will run it for a bit and then swap the sump gasket and re-torque the housing. the oil line is closer to the driveshaft than i would like so if that has any signes of touching after a few miles i'll mod that to be how i initially planned, the hydro shop gave me the stiffest braided hose known to man so i could not bend it into the block to be p-clipped.
other than that, fit the I/C when it comes back and i'm done!!!! lol i could have chose an easier swap for my first engine conversion!
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Well done mate. ;D
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Cheers Reg, I've learned a few thing whilst doing this, mainly to swap anything that 'might' need swapping whilst you have the chance.
This brings me onto my next point, what cheap/uprated clutch can i fit to hold with a mildly tuned engine?? the stock one now is slipping like a ***, either due to oil contamination or just wear (most probable as it's right at the top of the pedal!)
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and i recon the timing needs setting a little more advanced as the cold start lever makes it a little smoother even though it is not that cold!
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whered id you get that flexible intercooler hose?
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looks like pool hose to me.
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It's made for automotive use, good to about 1bar aparently. I got it from a local place that sells silicone parts. was £40 for 2m
Ry
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A GTD pump is built for single stage injectors, while a 1.9 has 2-stage injectors. Get a set of GTD 1.6 injectors for it.
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doubt that makes any difference, i do want to fit GTD injectors and new nozzles though in the future!
need help with the clutch!
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http://www.clutchnet.com/home.php (http://www.clutchnet.com/home.php)
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hoping for something in the UK really or with factory parts, is it an 8v disc and 16v pressure plate what i need?
Thanks!
Ryan
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Yeah an 8v disc with 16v pp I think will work...
I think my setup is a 210 mm PP and clutch with the small spline. I think it was the 8v scirocco setup if I am not mistaken.
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Yeah an 8v disc with 16v pp I think will work...
I think my setup is a 210 mm PP and clutch with the small spline. I think it was the 8v scirocco setup if I am not mistaken.
only reason you need a 16v disk is if you have a 16v or mk3 trans. otherwise its 8v disk and 16v pp. mine works great. plenty of holding power, way better than my stock 8v setup.
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I'm running the Mk3 gearbox so i'm assuming i need the complete 16v setup?
Thanks!
Ryan