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IP not woring properly
Posted: Tue Jun 28, 2011 5:35 am
by Estdub
Hello and greetings from Estonia
I am working on a 1,6 td (51 kw) diesel golf (rabbit). I managed to break one of the delivery valves and couldnt get it out. Instead i changed the distributor head and plunger as they travel in pairs. Now the problem is that two of the four delivery valves dont spray fuel when cranked. I tried to change them, but no luck, also primed the heck out of the IP . When the delivery valves where not installed then there was fuel coming out of the holes... what can be done to make these two delivery valves work again?
Re: IP not woring properly
Posted: Tue Jun 28, 2011 8:37 am
by 82vdub
Welcome to the forum. Is the car new to you, or do you know how well it ran before you started working on the delivery valves? What I'm saying is that if you don't know how it ran before you started working on it, there may be issues with the internals of the injector pump (IP). Can you give us a little more background information on your history with the car?
Re: IP not woring properly
Posted: Tue Jun 28, 2011 10:49 am
by Estdub
Thanks for the replay
i have owned the car for a year. most of that time it has not been started cos i changed the turbo from k24 to k14 to get rid of the turbo lag.
when i tried to start it the IP didnt pull up any fuel so i got another pump from a 1,6 td (59kw) and swapped those. it ran whit that pump, smoked a lot when revved . One of the delivery valves was a bit leaky and snapped when was trying to torque it down. The rest is described above.
tried to change those non working valves from another pump, but no luck. The ports spurt still fuel when DV-s are not installed so there shouldnt be a problem with the internals of the pump. i would take the pump to a specialist but the nearest is about 100km from here and whitout a car its a pain in the A**to get there
Re: IP not woring properly
Posted: Tue Jun 28, 2011 10:53 am
by Fatmobile
Do you have the accelerator floored when you are cranking it?
It pulls fuel from the pump now?
Is the max fuel screw turned in?
Re: IP not woring properly
Posted: Tue Jun 28, 2011 10:58 am
by Estdub
yes, i have the throttle and clutch pedals both slammed when cranking, the pump sucks fuel, and the max screw is turned as much in as it can be without removing the collar
Re: IP not woring properly
Posted: Tue Jun 28, 2011 11:17 am
by Fatmobile
Was the top of the pump taken off?
If so did they get the accelerator lever put back on right?
This isn't a common problem but I have heard of it before,.. can't recall what he cure was right now though,.. if there ever was one.
Any history on the head/plunger that got swapped on?
Re: IP not woring properly
Posted: Tue Jun 28, 2011 11:37 am
by Estdub
the pump top was not taken off. the history of the head/plunger is that they came from a non turbo working pump.
Re: IP not woring properly
Posted: Tue Jun 28, 2011 11:38 am
by Quantum-man
Have you had the delivery valves apart and wrongly assembled?
As there is only one high pressure piston, it can't realistically work for some and not others so the problem lies with the d/v's.
Swap a god one with a bad one, but do not take apart the good one, until you are finding the problem travelling with the delivery valve. At this time dismantle a good one and reassemble the torpedo insides of the bad one correctly...
There is one situation where the piston nolonger pressurises at one TDC angle, and that would be for the cam lobe to have disappeared. Seen it on a head cam [not my car] but that's about it 
Re: IP not woring properly
Posted: Tue Jun 28, 2011 1:48 pm
by Estdub
ill try tomorrow to switch DV-s tomorrorow... if that doesnt help then take it apart and change the plate with the lobes?
Re: IP not woring properly
Posted: Tue Jun 28, 2011 3:04 pm
by mtran
The Mark is said that you MUSTN`T exchange delivery valves parts,work on 1 only-that`s theory and most practise.
Re: IP not woring properly
Posted: Tue Jun 28, 2011 5:42 pm
by Quantum-man
mtran wrote:The Mark is said that you MUSTN`T exchange delivery valves parts,work on 1 only-that`s theory and most practise.
Agreed.
Just take apart a good one to see how a good one is assembled, after you have proved there are bad ones. If you have two , then prehaps inners are either back to front, or swapped... or just bad 
Re: IP not woring properly
Posted: Wed Jun 29, 2011 1:13 pm
by Estdub
hey there
managed to work with the pump a little. switched the working and not working DV-s and the result was that none of the valves worked... tried to switch back, but still no improvement... so now the pump is not spraying any fuel out of the DV-s. the dv-s are correctly put together... are there special techniques to install those valves or may i be missing something important in here? could there be something wrong inside of the pump besides the camplate?
Cheers
Ingmar
Re: IP not woring properly
Posted: Wed Jun 29, 2011 4:03 pm
by Quantum-man
Estdub wrote:hey there
managed to work with the pump a little. switched the working and not working DV-s and the result was that none of the valves worked... tried to switch back, but still no improvement... so now the pump is not spraying any fuel out of the DV-s. the dv-s are correctly put together... are there special techniques to install those valves or may i be missing something important in here? could there be something wrong inside of the pump besides the camplate?
Cheers
Ingmar
Number one suspect is your fuel solenoid not opening. Check for power and operation. Remove insides if neccessary. Pump will still lift and push fuel out of the out banjo even when switched off...
Re: IP not woring properly
Posted: Thu Jun 30, 2011 1:05 pm
by mtran
Do you use another fuel than D ?
Re: IP not woring properly
Posted: Thu Jun 30, 2011 2:29 pm
by Estdub
mtran wrote:Do you use another fuel than D ?
Yeah i usually use homebrew biodiesel but since i have changed the head i have used ordinary diesel from gas station. <So the pump is filled with good quality diesel.