Its been a learning experience to say the least.
Got it all together and running, albeit without timing the pump right.
went out for a drive in it and when you get to a certain rev its like I lift off the throttle and theres no go at all.. Doesn't go much faster than 40MPH just flat I assume the LDA and pump wasn't set right or timed with a gauge just by ear and how much smoke came out the back..
Now the unknowns with this engine are:
Injectors (Came with a recon head the guy bought with the block)
Pump, came off the other engine.
Bottom End was never taken apart as the guy didn't want to.
The flywheel I dont think was a JX as when the JX clutch arrived it didn't line up with the dowels, was asked to make it fit so removed two dowels...NOT ideal at all.. but hey do what im told.
I've no idea on how much the fuel screw on this pumps been adjusted as the crimped covers been removed and some of the threads are abit buggered, so I don't know if that's OK I guess wind it in for more fuel? wind it out for less after loosening the 13mm nut? Just need a base to start from.
Set the pump to .95mm with everything timed right in place..
Smokes like crazy (white diesel) from cold with the cold start on runs a bit smoother but still diesel smokey.. backed off (away from head) runs even worse, more towards the head runs better at idle Im thinking time the pump to 1.00 or more if I can?
Boost pin was gummed up and set on the lowest movement, turned it 180 degrees so we got max pin movement.
Went out for a small test drive in it Sunday after timing the pump with the gauge and moving the pin, it had more go and pickup however still didnt want to go more than 50 flat out, then the oil light came on after a mile and pulled over to check, engine was incredibly warm I know EGTs are very important with diesels but no way to test them.. anyway he decided to carry on after I checked the wiring and the light went out.. and putting the heater on and it came through hot ( the wirings.. well its a thing, put it that way.. was an Aircooled van )
Next thing I know I start hearing a pretty nasty knocking/rattling sound and smoke billowing out the back of the van from the exhaust. Got him to pull into a pub carpark and let it sit, decided to tow it back to his house as to not damage things further.. if it hasn't died a death already. The knocking sounded like it was coming from the bellhousing rather than bottom end, I hope.
No coolant leaks anywhere just a very very very hot engine, took the breather off the case and its was smoking from it.
rad gets warm but not super hot.. the thermostat was never changed as he was just gonna reuse what was on the old engine as it "worked" so I was thinking maybe thats stuck. Pipe from thermostat I could hold as it was warm but the other hoses were scalding to touch.
Now when putting all the 1.6 bits onto the AAZ aside from the vaccum pump it still has the JX pulleys for the waterpump and alternator, currently its a one belt setup.. there doesn't seem to be barely any belt against the waterpump pulley and I could move the pulley with my hands until I really levered on the alternator to pull it up enough to its maximum.. Im concerned that either the pump is slipping and not pushing coolant around causing it to overheat or the thermostat is stuck closed. Heater comes on warm no hot cold hot cold so must be getting pumped around... but I was just wondering if the pumps been slipping. Is there a better way to do the water pump and alternator pulleys with the JX pulleys?
