Turbo conversion won't go!!

[Bluevanman!]

At long last i have finally swapped over my 70ps for a turbo engine! Took me a week, prepping the replacement engine, clutch, new manual pump (146) water pump etc.. and removing old engine and using a few bits off that to put on the turbo engine. Big job!!!!!!!

I have the engine in everything on, got fuel to the pump. Now i cracked off the pipes to the injectors and there is fuel getting there but not allot. Just kind of very slowly seeps from around the loose nut in each injector. I have fueled up the pump, stop solenoid is working fine.
I Replaced all the belts, cam belt. Timing is spot on lining up the holes etc, I know you have to line up the pump by loosening the 4 bolts on the pulley to get the injector timing spot on but from what i here on this forum people get there engines going but just adjust this plate to fine tune the running of the engine "right" ?? So i guess this is not a big deal until the engine runs?
With the injectors tighten it won't try to start. I have turned over the engine lots and lots of times for 10 sec each time. But gave up in the end fearing i will kill the starter! And the duel batteries are taking a pounding too! Did this over 2 days while doing other little tasks to the van.

I'm thinking there may be a problem inside he pump? I bought the pump off a seller on ebay who re-conditions pumps. It is in almost mint condition so i have no reason to think it's that but just want some more Opinions on what it could be or what i could try??

I have has the engine turn over by spraying a little easy start in the air intake and the engine sounds smooth and just like my dads TD tourneo.

Any suggestions would be great!!! bare in mind i have very limited experience with fuel pumps!!!

Thanks!!

Ps i wouldn't of even attempted this if it wasn't for this great fourm!! Great resource of information!!!!

[madmark_50484]

Going on what you have said sounds like the pumps a bit had it but at least you know its a fueling issue as you can run it on easy start

might also be worth checking filters and pipes

[Bluevanman!]

Hmm, i hope not but it is worth considering.

I forgot to mention that the pump was sitting in storage for 1 year as was the engine before last week. The pump was kept in a well packed box in my shed and the engine On a pallete.

Thought i would mention this in case it has a bearing on the fueling issue
.

[MinorMatt]

Have you bypassed the immobiliser or swopped the rim module from your existing pump? (dependant on year)

[alanwh]

Have you got fuel returning to the filter from the pump when cranking ?

[psv-hgv-flt]

pipes to pump wrong way round, or if it is trying - air in fuel, dodgy pipe, or lift pump.. ???

[dodgy01]

you really need to start at the tank then work your way to the injectors eliminating 1 thing at a time
so check that there is fuel at the lift pump then check the lift pump is putting out fuel and tract this pipe to the filter, then check fuel coming out of the filter to the injection pume it should come out of the pipe going to the inj pump at the same pressure as from the lift pump
if all this checks out ok then its the diesel pump
good luck

[duratece30]

Easy way to by pass a lot of things is to fill a bottle with diesel, drill a hole in the top just big enough to squeeze a bit of fuel pipe through. connect other end of pipe to inlet on injection pump, tip bottle upside down so that fuel is covering end of pipe and hold as high as possible to aid gravity. Crank the old girl over and see what happens, if she fires into life then start looking backwards towards tank, if not make sure your solenoid is working, or even take out the spring and plunger from it to be 100% sure ( but if she fires up you'll have to stall her to get her to cut out), if still nothing really coming out at injectors you can say it's the pump. No matter how far out your timing is as long as the pump is turning then you should have a good fuel flow at the injectors.

[MIXA]

All very good advice just a matter of elimitation unfortunatly , BUT DONT GO USING EASY START, IT WILL GET SO IT WILL NOT GO WITH OUT IT , my old mk 2 was a company van and when the heater plugs started to play up they used that stuff it refused to even think of starting with out a wiff even with new batterys , heaterplugs and starter,after.

[bazw]

i would second matt about the cut off

small dribbles tend to mean the cut off is not opening

if you have bye-passed it, try popping it out and removing the plunger and spring , replace body and try to start (crack open the union to #1 injector so it bleeds the system ) , if it fires up the cut out is duff or not working right and an easy fix so just stall the engine in gear , nip up the union and bung a new cut out in or clean up the connections and where the plunger slides to try to fix old one

if it does not fire up

did you advance the pump timing as per the thread on fitting the 145/6 pumps to a turbo engine ?

[psv-hgv-flt]

All very good advice just a matter of elimitation unfortunatly , BUT DONT GO USING EASY START, IT WILL GET SO IT WILL NOT GO WITH OUT IT , my old mk 2 was a company van and when the heater plugs started to play up they used that stuff it refused to even think of starting with out a wiff even with new batterys , heaterplugs and starter,after.

NO SUCH THING,(ITS NOT HUMAN) if he has to use that there is still a problem.

[Bluevanman!]

Have you bypassed the immobiliser or swopped the rim module from your existing pump? (dependant on year)

I removed the stop sollenoid from my old pump as the re-con pump didn't have the solenoid fitted. The solenoid works. When i dissconnct the live from the top of the solenoid and switch on the ignition and touch the terminal with the connector i can hear the solenoid valve click in strong. So im sure the stop solenoid is not at fault. I hope!!!!!!

[Bluevanman!]

Thanks for all the sugestions, i will have another go later today if i can get out of shopping with the girlfriend!! haha!

Just to mention, i did have a problem with the lift pump. It wouldn't lift from the tank but found that the inlet from the tank onto the lift pump was ever so slightly loose. Enough to let air in. I solved it by using a pipe clip and made a tight seal and then the fuel Was pouring out of the union that goes into the pump. Filter is new and full of fuel to.

I will check today if there is still fuel geting to the pump and that the pump solenoid is clean and no dirt has got in there. Worth a look!

Pump was set up as per the 146 guide on this fourm to.

Will post back later today on my progress with the van!!

[Bluevanman!]

Right!! It runs!!!!!!!

It was the fuel pump (injector pump)
I took the old injector pump off my old DI fitted it to the turbo motor and within a few turns it was away!!! brill!!!!

So there is a problem with my supposed re-conditiond pump.

Any idea where i could send it to be looked at?? Is it a joob i could have a go at??
Or should i just get another pump.
The pump on the engine now works but aware it.s not the recomended 145,146 pump i think its a 125? Didn't realeigh look. Just wanted to get the engine to run!

Going to carry on with the van in the new year now!! need a rest from it!!