A new thread, dedicated to starting my diesel.

[smithy010]

Ok,
So today, i started at 4pm, to change out and replace my petrol with the diesel engine.
All things went roughly to plan. It's now pretty much all fit up.
I have to replace the earth lead, but for now, i just used a jumper lead in parallel with the ****ty little earth lead.
So i cranked it over, and it sucked fuel up from the tank and everything, and fuel was evident at the injectors, and at the return line, but no go...

Gotta charge the battery up again (it's not totally flat, but could do with a charge).

My planned angle off attack is to go over it, and double check that the timing is correct.

Any hints o wise ones?

Smithy

[brackie]

Glow plugs

I don't know what mods you did to your wiring but if there's no glow there's no go! Check each glow plug for current. I assume you installed the correct glow plug relay and fuse

[smithy010]

I installed a 60 Amp glowplug relay, with 50 amp fuse, connected to a switch on the dash. I will try glowing for longer... I was probably only glowing for 10 seconds (temperature about 15 degrees)..

The plugs were definitely heating.

Cheers Brackie.

Smithy

[smithy010]

Ok, so i have managed to get a small sign of life out of it. After turning it over a while, it started to sputter, and produce a small amount of smoke. I realised that at that stage, the injector pipe for pot 1 was detached, but no fuel was coming from the outlet...

What could cause this?

[brackie]

Air

You probably have air in the system. Did you prime the injection pump before attempting to start it? It must be full of fuel before it's put under load. Any air in the pump will (of course) rise to the top of the pump body and this may explain why you're getting fuel in some rails but not others.

[smithy010]

I was under the impression that the pump did not need priming...

I haven't got my bentley with me at the moment, can you go through the process for me brackie?

[smithy010]

Sorry Dudes, i just did a little search on the forum and found a bit of material about bleeding the air.. uhhh, i mean fuel system.
So correct me if i'm worng, but if i crack the injector pipes (all 4 of them), and wind her over until fuel weeps from all of them, and ensure there are no air leaks downstream, then bob will be my uncle?

[brackie]

Bleeding system

Smithy, you were talking about the CAV filter. If you're using an early one, it'll have a priming pump so loosen off the bleed screws and pump out the air. When I have an injection pump off I (obviously) replace the fuel filter but fill it with clean diesel before attempting to start the motor (whether it's a CAV or a later type with a water drain tap).
On top of the IP are two banjo unions with hoses connected. The one with only one hose and comes from the filter is obviously the inlet and the one with 2 hoses is the "vent screw". One of these (the smaller hose) is the injector bleed-off hose and the large one the return to the filter/tank.

1. Disconnect the glow plugs (or don't activate them)
2. loosen the vent screw but leave the injector lines connected
3. with the throttle wide open turn over the motor until diesel with no air emerges from the loosened vent screw
4. tighten the vent screw and #s 2 and 4 injector lines and turn the motor over again until you see diesel emerging.Tighten them
5. do the same with injector lines 1 & 3.Tighten them
6. glow the engine for 20sec
7. with the throttle wide open turn over the motor until she starts

It'll run rough until all of the air is bled out of the system. The VE pump has a air bleed poppet valve so eventually it will dispel the air and run smoothly.

8. Go and open a beer

Also, are you aware the two banjo unions are different? The "vent screw" has a restrictor and should not be swapped with the fuel supply line. I hope that all of the hoses in the line from the tank to the filter are good. Even the slightest air leak will result in air accumulating in the highest point (the filter) and the motor will not run.

[smithy010]

THANKYOU BRACKIE!
I will try this right now.

[smithy010]

It lives!

Yep. That's right, Smithy now has a diesel!

I followed Brackie's directions, and after a bit of cranking, she went. It goes quite nicely, which surprised me somewhat because i figured i would need to adjust the timing at least a bit, but it appears the timing is close to spot on.

I have one problem...

When i stop it,, fuel runs back into the injector pump from the return line, and then when i try to start it again, it takes a bit of cranking to get it to go...

I've checked all over for air leaks.. The only thing i can forsee is that there is a small air leak in the return lines that link the injectors... but that doesn't explain where the fuel is going...

Any suggestions.?

I also need to modify the crankcase breather for the anti over-run thingo.

Smithy

[Golf Loon]

Nice work Smithy.
I reckon you deserve that beer.
Proud owner of a swallowtail diesel

[hiho]

Where are the photos?

Photos please, i wanna see your car and your grin!

[brackie]

Well done, Smithy!

It's been a long proces, but success at last. Well done, mate

[smithy010]

It's only been a long process because i've written a thesis in the last year as well, but yes, having a diesel has been my dream for over 12 months now, and i'm glad to have a good one.

It doesn't blow any smoke except on starting and a bit of white smoke under power only when cold.

NOW, to start a list of the things that will keep my diesel going for as long as possible.
Anyone got any tips on increasing the longevity of my diesel?

I'l start it:
1) Use good oil and coolant: but what does this mean?
2) Fit the anti over-run mod.
3) Warm up for a couple of minutes before starting off.

I'll post pics soon.
Oh, and thanks to everyone on the forum for their generosity with knowledge and parts to make this happen!

[brackie]

Tips

It's only been a long process because i've written a thesis in the last year as well, but yes, having a diesel has been my dream for over 12 months now, and i'm glad to have a good one.

It doesn't blow any smoke except on starting and a bit of white smoke under power only when cold.

Unless the "smoke" is steam on a very cold morning, it means your timing is slightly retarded. Best to check it.

NOW, to start a list of the things that will keep my diesel going for as long as possible.
Anyone got any tips on increasing the longevity of my diesel?

I'l start it:
1) Use good oil and coolant: but what does this mean?
2) Fit the anti over-run mod.
3) Warm up for a couple of minutes before starting off.

Use a general purpose diesel engine oil until it loosens up. I use "Valvoline Blue". Then go to semi-synthetic once the rings have bedded in. I've never used a fully synthetic oil in a 1.5D so I can't comment. Use G12 coolant.
Make up your crankcase breather. Somewhere on this forum (do a search) is the mod that I did and it's still working a treat
It's better to drive straight off from cold. Warming the engine risks glazing the cylinder walls as there's very little load. This is especially important after a rebore/hone or with a brand new engine. If she doesn't pull well use the cold start to advance to timing. It's Ok to use it until the engine warms up.
Change you oil and filter and fuel filter before 5000km and check the torque of the cylinder head bolts and camshaft sprocket (if that slips, you're stuffed!)

Oh, and thanks to everyone on the forum for their generosity with knowledge and parts to make this happen!

No worries mate! We've got to keep as many of these diesels on the road as possible