diesel rabbit no start
Posted: Fri Sep 21, 2018 7:30 am
Hello all, this is my first post so please deal with me. this is also my thread from vw vortex, but maybe someone on here has some more helpful info..
I bought a 1980 diesel rabbit 1.5l about 2 months ago. When I got it was not running. Replaced a few small items at the beginning of troubleshooting. Swapped all 4 glow plugs and no luck (also replaced the solenoid on the injection pump). Finally realized the bus bar was making poor contact, got a new one and the car ran great for about 2 weeks. Then, the injection pump started leaking. Got one through someone on the forums with the fuel governor taken out. Took the car apart, made sure everything was at TDC, replaced the injection pump, timing belt, and v-belt . Filled the injection pump with fuel and turned it over. No fuel came through the fuel rails. Injection pump is getting good fuel in, and the return line is full of fuel also. So, I assumed it had to do with the solenoid on the injection pump. So I replaced the one on the new pump with the new one I previously bought. When I did that the wire (that was holding on by a thread of metal) and the eyelet came apart. So instead of replacing it the proper way, I pulled back some of the wire jacket, and screwed that back on to the solenoid I had on my old injection pump (probably not the best idea but it was only for troubleshooting) turned the car over, and the glow plug light lit up for about 2 seconds and instantly went out (usually it stays on for 7, and the flickers out) still no fuel coming out of the fuel lines. Also noticed a slight burning smell coming through the vents. After that I was pretty distraught after being at work all day and left it there.
Was wondering what my first step in trouble shooting should be? This is my first mk1 and I am not too familiar with the or diesel in general. I was told there is a fuse panel on the inside of the firewall where the ground from the injection pump solenoid goes. (hopefully that’s that burnt) if not I will check the relay under the dash?
Any help is appreciated!
UPDATE:
finally got fuel to all 4 injectors (with a whole lot of priming and a battery swap)
hard wired the injection pump solenoid to the battery so i can rule out the solenoid not working. Also tested and confirmed that solenoid gets a full 12.5 volts with multimeter.
Re-confirmed car is all timed correctly. (unable to time injection pump due to not having a dial.)
Replaced glow plug relay under dash.
Replaced hose from fuel pump (mounted in engine bay) to the injection pump with a clear hose. (no noticeable air bubbles in hose)
Replaced fuse in back of firewall (old one still looked good)
Now it seems if i leave the hard wired relay on the battery the whole time before i try to start it i will not get a GP light. if i kind of mess with it on the battery i can get the GP light to come on for about a max of 5 seconds. try starting the car right after still no start. I can hear the solenoid click when i connect it to the battery so i know its functional.
when i check the glow plug bus bar with a multimeter and turn the car over (not starting) i get about 11.8-11.9volts, for about 7-10 seconds, then i hear a click in the car (assuming a relay) and then the glow plugs drop voltage to 0.0 (not sure if this is supposed to happen)
seeing as i get fuel and spark, the only other thing i can think of is compression. haven't checked but the car ran before the injection pump started leaking, so i am assuming its still good.
Any help on the next step of trouble shooting would be great!
new note: i was also told the pump could be 180 out. i have everything spot on, including the mark on the inside of the pulley. could the mark on the pulley actually be 180 off, and instead be at the bottom and not the top?
I bought a 1980 diesel rabbit 1.5l about 2 months ago. When I got it was not running. Replaced a few small items at the beginning of troubleshooting. Swapped all 4 glow plugs and no luck (also replaced the solenoid on the injection pump). Finally realized the bus bar was making poor contact, got a new one and the car ran great for about 2 weeks. Then, the injection pump started leaking. Got one through someone on the forums with the fuel governor taken out. Took the car apart, made sure everything was at TDC, replaced the injection pump, timing belt, and v-belt . Filled the injection pump with fuel and turned it over. No fuel came through the fuel rails. Injection pump is getting good fuel in, and the return line is full of fuel also. So, I assumed it had to do with the solenoid on the injection pump. So I replaced the one on the new pump with the new one I previously bought. When I did that the wire (that was holding on by a thread of metal) and the eyelet came apart. So instead of replacing it the proper way, I pulled back some of the wire jacket, and screwed that back on to the solenoid I had on my old injection pump (probably not the best idea but it was only for troubleshooting) turned the car over, and the glow plug light lit up for about 2 seconds and instantly went out (usually it stays on for 7, and the flickers out) still no fuel coming out of the fuel lines. Also noticed a slight burning smell coming through the vents. After that I was pretty distraught after being at work all day and left it there.
Was wondering what my first step in trouble shooting should be? This is my first mk1 and I am not too familiar with the or diesel in general. I was told there is a fuse panel on the inside of the firewall where the ground from the injection pump solenoid goes. (hopefully that’s that burnt) if not I will check the relay under the dash?
Any help is appreciated!
UPDATE:
finally got fuel to all 4 injectors (with a whole lot of priming and a battery swap)
hard wired the injection pump solenoid to the battery so i can rule out the solenoid not working. Also tested and confirmed that solenoid gets a full 12.5 volts with multimeter.
Re-confirmed car is all timed correctly. (unable to time injection pump due to not having a dial.)
Replaced glow plug relay under dash.
Replaced hose from fuel pump (mounted in engine bay) to the injection pump with a clear hose. (no noticeable air bubbles in hose)
Replaced fuse in back of firewall (old one still looked good)
Now it seems if i leave the hard wired relay on the battery the whole time before i try to start it i will not get a GP light. if i kind of mess with it on the battery i can get the GP light to come on for about a max of 5 seconds. try starting the car right after still no start. I can hear the solenoid click when i connect it to the battery so i know its functional.
when i check the glow plug bus bar with a multimeter and turn the car over (not starting) i get about 11.8-11.9volts, for about 7-10 seconds, then i hear a click in the car (assuming a relay) and then the glow plugs drop voltage to 0.0 (not sure if this is supposed to happen)
seeing as i get fuel and spark, the only other thing i can think of is compression. haven't checked but the car ran before the injection pump started leaking, so i am assuming its still good.
Any help on the next step of trouble shooting would be great!
new note: i was also told the pump could be 180 out. i have everything spot on, including the mark on the inside of the pulley. could the mark on the pulley actually be 180 off, and instead be at the bottom and not the top?