1.6 TD läuft nicht richtig Einspritzpumpe einstellen | Posts 48+

I would like to express my sincere gratitude to everyone who has helped me here.

My Caddy passed the technical inspection (TÜV), the individual inspection, and the emissions test on the first try, even though the emissions test was a bit of a challenge. With one more entry, the vehicle registration document would even be three pages long.

I've already driven 1000km and I think the car is amazing. The engine's performance has improved significantly since the first 200km. Now, I think I just need to fine-tune the fuel injection system. It's lacking power at higher RPMs. I can only reach 155 km/h on the highway according to the speedometer, even though the vehicle registration document states that it should be able to reach 169 km/h.

He's getting massive black smoke at over 70% throttle until the turbo kicks in, then it clears up. I think there might be a problem with the LDA (likely referring to a diesel injection control unit). Smoking is significantly more harmful when inhaled deeply.

I had to turn the full-throttle screw to adjust the rev limiter, so it cuts out at 5000 RPM instead of 5700. However, it feels very restricted now and I could only barely reach 110 km/h. I suspect that's where the problem lies. But I don't want to turn the screw any further in that direction. Even at a standstill, with the accelerator fully pressed, the engine's RPM is already too high, according to the built-in tachometer.

"Additionally, I'm experiencing a problem where the engine speed is quite low when starting, and it sometimes runs unevenly during startup. After a few seconds, the engine speed increases from 750 to around 950 RPM." He maintains that value, around 950, permanently.

So, I'm wondering if anyone has any advice for me on how to best adjust the pump, or if there might be another issue causing the problem.

Hi!
Well, congratulations!
Nice car... if I had the time and inclination... it might even appeal to me.

Is it registered as a truck?

Subject: Top Speed.
I can't help you with the pump.

First of all, I wouldn't stress too much about trying to reach 169.
The car has a completely different aerodynamic profile compared to, for example, a Golf.

And then you can check if the correct gear is engaged.
At the time, it was like a modular system, where you could put all sorts of things together in a very flexible way.
That's happened to me before, with my Golf TD.
I installed a used transmission, but it was originally from a gasoline-powered car.
That was translated with a higher degree of accuracy.
The car, although it had plenty of torque,
but it also didn't reach its top speed.

Hi,
Do the injectors still have the poor spray pattern/ "leaking" issue described earlier? If so, you don't need to look any further. That's going to cause trouble.
Otherwise: Valve lift of 0.90 mm at TDC, new injection pressure of 163 bar, wear limit of 140 bar; boost pressure should become noticeable around 2500 rpm.
The fact that smoke decreases with increasing boost pressure only indicates that, with more air, poorly or excessively injected fuel burns more completely.
hg
Herbert.

Okay, I replaced those nozzles a long time ago. When I did, I installed new nozzle bodies and adjusted the pressure to the value that was indicated on the nozzle housing. I mean 155 bar.

I think I need to let the engine warm up and run freely for a bit before using it. The boost pressure is now reaching approximately 2500, and the smoking issue has been resolved since I rotated the LDA cone back to its stock position.

It's burning much better now. There's a very small puff of gray smoke during cold starts, and a small puff of black smoke when revving the engine while stationary. However, it's completely smoke-free during normal driving. It only smokes briefly in the first moment when you fully accelerate.

The gearbox was initially the wrong one. I was aware of that. It had a 5-speed gearbox installed, which I believe is a 4-speed gearbox from a naturally aspirated diesel engine. It was terrible to drive. At 100 km/h on the country road, you felt like you were already hitting the speed limiter. Currently installed is an ATH (Automatic Transmission Housing), which is identical to the one originally fitted to the engine, except for the flange sizes of the drive shafts.

Otherwise, according to the speedometer, it now reaches its maximum speed. However, I think my intercooler is a huge problem. It's located in the engine compartment, just like the original one on a Golf 2 GTD, which is not ideal. However, I am missing the original air ducts.

When I drive with a heavy load, it warms up quickly. The coolant temperature is just above the first mark above the middle. The oil temperature also quickly rises towards 95 degrees, even though the outside temperature is between -5 and +5 degrees Celsius. You can also see how the intake air seems to get too warm when driving with full throttle for an extended period. He starts to get the black smoke coming out the back.

I'll probably fabricate an air duct for him soon and see if that resolves the problem. I'd really like to keep the intercooler in the engine bay for aesthetic reasons. I think the placement above the gearbox is really cool, even though I have enough space in the front, in front of the water cooler, to put it there.

Okay, here's a picture of the engine bay attached. I actually find it incredibly cramped. It's not ideal for the intercooler at all. There's a huge battery right in front of it, and where the windshield washer reservoir is in the picture, there's currently a Webasto Thermo Top C auxiliary heater installed because I had one lying around, and I thought it would be cool to have a heater in a 35-year-old Caddy. And yes, it's registered as a truck and doesn't have a "H" license plate. I highly doubt that he can get H-plates (registration for vehicles adapted for disabled people) with that kind of water heater, even though it was already available as an option from the factory in similar model years for the T4.

Well, I'm definitely more than satisfied with the planter.