From: borowski@hpspkla.spk.hp.com (Don T. Borowski)
Newsgroups: rec.autos.tech
Subject: Re: Diesel questions
Date: 8 Apr 92 15:10:22 GMT
Article-I.D.: hpspkla.31160038
Organization: Hewlett Packard Company, Spokane, Wa.

In rec.autos.tech, jniewiad@csws7.ic.sunysb.edu (Jan Jozef Niewiadomski) writes:
>
>I have some questions about my 81 Rabbit (diesel).  I just got my car back
>from the body shop and it's not running well...(no surprise here).  Anyway,
>after spending $2.5k on body work I'm NOT wasting my money on morons who 
>claim to know diesels.
>
>  The problem is the following:
>
>    -The car starts up right away (cold morning, SAE 30, never smoked
>    before accident), however, it runs very unevenly for about a minute.
>    and it makes a lotta smoke.  It runs well after it warms up but it 
>    still smokes a little at high revs and the dieseling sounds a little 
>    louder so I think that the timing might be retarded a bit.

Don't forget to check the glow plugs and the glow plug fuse.  On cold mornings
a burnt out glow plug will cause more smoke and rough running until the engine
warms up a bit.  I bought one of those ampmeters from the auto parts store
that you just lay on the wire.  After I replaced two burnt out glow plugs,
I placed it on the wire feeding power to the glow plugs, and measured the
current, and wrote down the measurement so that I can now easily determine
if one (or more) has burnt out.

>    -They replaced the lines to injectors 3 and 4 and I suspect they
>    might have gotten dirt in those injectors which is causing a poor
>    spray pattern.
>
>    -They had to remove the timing belt to weld the new mount on the 
>    chassis. I know the valves aren't bent because I made sure they turned
>    the motor by hand before they started.(Also no popping sounds from the
>    intake manifolds, and even running at op temp)
>
>I plan to redo the timing myself (no problem here), the problem is with the
>injectors.  Is there any voodoo to removing them as the dealers and books
>suggest or do I just screw them out(cold engine), check the atomization, put 
>them back in with new heat-shields and anti-seizing compound ?

I hope you have the cam lock special tool, injection pump lock special tool
(or a socket of the proper diameter), injection pump timing measurement
adaptor, and dial indicator.  You need all these to properly set the timing.
We have a VW diesel owners' club here at work, and have purchased these
special tools.

I have replaced the injectors myself, and it is no big deal.  Just do as you
plan.  It is helpful to loosen the injector lines at the pump end so you can
move them out of the way of each other and the injectors.  I have never
checked the spray pattern as you suggest, though I see no problem.  You will
probably get some air in the injector lines during the removal process, so
crank the engine and apply some throttle to get it out.  You will probably
want to have the rubber fuel return lines connected so that you minimize the
mess.

Make sure you use a torque wrench for replacing the injectors.  You will
also need a deep-well socket, either 27 mm or 1 1/16" (only .0005" 
difference between them.  I sure they both come off the same line, and then
are labeled).

>    Also:
>     Can they be reassembled if I dismantle them?

Yes.  The main body is two pieces, one screwed into the other.  Just make sure
to keep things ABSOLUTELY clean.  There are no gaskets, so any dirt at the
joint will allow fuel to leak.

>     Anyone know if I can get new ones in the NY area for less than $90?

I can't help you there.  At one local independant auto repair place that
specializes in VW, they will rebuilt injectors for $45 plus parts cost for
new nozzles if necessary (about $15 per nozzle).  Older injectors will
typically need pressure recalibration, even if the nozzles are OK.  I just
bought a set of Bosch rebuilt ones for about $140 exchange, and just had my
other set recalibrated for $45.

>This was my first car and I'd like to keep it for years to come...Any ideas or
>suggestions for other things to check or look out for would be appreciated.
>Please post or reply.

My '81 Rabbit is my first car too, and I'd like to keep it for years to come.

>Thanks in advance.
>
>JJ

I have 138,000 miles on mine.  My nephew just bought one with 140,000 miles
on it, which needs a lot of work (we will be seeing a lot of each other on
Saturdays).

I have a lot of stories.  E-mail me if interested.


Donald Borowski    WA6OMI    Hewlett-Packard, Spokane Division
"Angels are able to fly because they take themselves so lightly."
                                       -G.K. Chesterton
Newsgroups: rec.autos.tech