Updated !!New Injector pump = no power, lots of smoke and knocking

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greg lousy
Turbo Charger
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Location: Rhode Island

Re: Updated !!New Injector pump = no power, lots of smoke and knocking

Post by greg lousy » Sun Nov 25, 2018 6:56 pm

Damn. Been gone a while and come back to this heartbreak. Im gonna take a step or 2 back because im not yet sure this new leak on this second pump is the real boogey man.
Did you turn belt by hand after first or second pump swap? First timing belt? Theres a few marks on the flywheel, sure youre on the triangle/ arrow one? ... going way back... yes, better to get cam amd crank in the viscinity of TDC with old belt still on. Also, more exact to put equal feeler gauges under cam locking plate because theres still play with plate in there. And always rotate after. Depending on IP locking mechanism and how you happen to do things you can still end up in the overly retarded range of ip timing and have to move belt a tooth. Dial gaige measurement helpful here
I know fuel delivery has been adressed, but have you done a straight up bottle feed? Personally i wouldnt settle for permantly on additional fuel pump.
Also... i couldnt see pictures of bad plug and injector for some reason, but did that damage occur just from brief test running while youve been doing this? Thats the main thing making me suspect some bigger problem than leaky pump. And the noise. Is that mechanical fail sounding to anyone else?
If it was me, i would seperate the pump from anything else by putting the injectors lines on backwards pointing the injectors up in the air, put up some cardboard shields where you dont want diesel (like the belt ) and take a look. I think i learned that here.... kind of a done screwing around move.
..... damn
And also i am 2 for 2 on good pumps from jack.
Various vehicles in various states

greg lousy
Turbo Charger
Posts: 224
Joined: Thu Apr 05, 2012 12:22 am
Location: Rhode Island

Re: Updated !!New Injector pump = no power, lots of smoke and knocking

Post by greg lousy » Sun Nov 25, 2018 8:23 pm

Also, same noises with this 2nd pump?
Various vehicles in various states

SheetsC
Glow Plug
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Location: Linville Nc

Re: Updated !!New Injector pump = no power, lots of smoke and knocking

Post by SheetsC » Mon Nov 26, 2018 8:07 pm

Thanks for the reply.
The timing belt is new and I rotated it server times after install.

There is a diamond shaped notch on the fly wheel and a fixed notch that lines up top dead center.
The cam locking tool is best I can tell parallel. No room for gauges.
I am sending this pump back yet again for a new one so hopefully third times a charm.

However I do suspect something else is not working properly bests I leaking pump.
I will try bottle feeding with new pump(with inline filter).
1981 Rabbit two door 4 speed(future daily drive)
1982 Caddy 5 speed(past ten year daily driver)

Fatmobile
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Re: Updated !!New Injector pump = no power, lots of smoke and knocking

Post by Fatmobile » Thu Nov 29, 2018 11:18 pm

Can you put it at TDC and post a picture of the flywheel timing mark you are using?
'91 Golf gasser converted to turbo diesel.
'83 Rabbit gasser, converted to diesel, then converted to run on vegetable oil.
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greg lousy
Turbo Charger
Posts: 224
Joined: Thu Apr 05, 2012 12:22 am
Location: Rhode Island

Re: Updated !!New Injector pump = no power, lots of smoke and knocking

Post by greg lousy » Sat Dec 01, 2018 11:06 am

"Diamond notch" sounds like the one, but worth verifying. Lining up crank and cam seperately you kind of lose frame of reference. Someone on here once mentioned flywheel installed 180 degrees off. Theres a way to test tdc from cylinders and not flywheel if you want to check. Its on this site somewhere. Hand turning crank and feeling and listening for damage worth doing too

Noise as far as i could hear is not anything ive heard with my share of IP fails, (3, including high pressure side leak).
Various vehicles in various states

SheetsC
Glow Plug
Posts: 23
Joined: Sun Aug 12, 2018 8:26 pm
Location: Linville Nc

Re: Updated !!New Injector pump = no power, lots of smoke and knocking

Post by SheetsC » Wed Feb 06, 2019 6:35 pm

Finally warmed up enough here in western NC to get some car work done.
I got the newly rebuilt injector pump installed. Attached are TDC photos.
Tmrw I will fill the pump with ATF and prime the lines and hope she turns over fires up and runs great.

Pump came with new OUT bolt which was nice. It didn’t come with a cold start cable rod so I made one by drilling two holes into a socket and tapped one hole to run a small bolt into the cable. Works pretty well so far.
Not super optimistic given my string of failures but at least we should be able to eliminate some factors.
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1981 Rabbit two door 4 speed(future daily drive)
1982 Caddy 5 speed(past ten year daily driver)

greg lousy
Turbo Charger
Posts: 224
Joined: Thu Apr 05, 2012 12:22 am
Location: Rhode Island

Re: Updated !!New Injector pump = no power, lots of smoke and knocking

Post by greg lousy » Wed Feb 06, 2019 9:10 pm

Timing stuff looks ok to me.

Where were we? Bottle feed? Crank by hand?
Various vehicles in various states

SheetsC
Glow Plug
Posts: 23
Joined: Sun Aug 12, 2018 8:26 pm
Location: Linville Nc

Re: Updated !!New Injector pump = no power, lots of smoke and knocking

Post by SheetsC » Thu Feb 07, 2019 8:34 pm

No luck getting her running today. Fill up IP with ATF
She did start for about ten rough seconds then died.
Turns over and acts like it’s getting ready to fire up but nothing. Smoke out of the tail pipe is grey and white.
Primed lines by cracking injector nut one at a time while cranking.
I have Vince Walden glow plug system upgrade and I’m getting 13.1 v to each glow plug. Which I checked by taking injectors out and looking down the holes.
I will keep at it tmrw
1981 Rabbit two door 4 speed(future daily drive)
1982 Caddy 5 speed(past ten year daily driver)

greg lousy
Turbo Charger
Posts: 224
Joined: Thu Apr 05, 2012 12:22 am
Location: Rhode Island

Re: Updated !!New Injector pump = no power, lots of smoke and knocking

Post by greg lousy » Thu Feb 07, 2019 10:46 pm

Have you turned engine by hand yet?
Suspecting more and more theres a problem in the belly of the beast.
Various vehicles in various states

SheetsC
Glow Plug
Posts: 23
Joined: Sun Aug 12, 2018 8:26 pm
Location: Linville Nc

Re: Updated !!New Injector pump = no power, lots of smoke and knocking

Post by SheetsC » Wed Feb 20, 2019 10:44 am

After replacing all 4 injectors and heat shields and the right most glow plug she fired up fairly easily and idles well after warm up.
It smokes Much less but still has to much white and gray smoke. I will trying advancing the timing soon.
Also I think my lack of power problem has been that my accelerator cable is all whacked out. I am trying to replace with new cable but the new cables don’t come with a rubber grommet that lives in the firewall. Just the green hard plastic piece.
Anyone have any suggestions?

Thanks
C
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1981 Rabbit two door 4 speed(future daily drive)
1982 Caddy 5 speed(past ten year daily driver)

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