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Discussion Starter #1
I finally got the motor swap on my 1981 VW Caddy 1.6l diesel. Change fuel filter and fill with fuel and also fuel pump. Gave it a little starting fuel and it cranked right up and ran about 30 sec. Hit the starter again and ran for about 30 sec. During this 30 sec I pulled the choke and the motor died right then. Can start the engine every time and this happens. During this running it is really rough. Also I let the glow plugs do there thing each time. Do you think the fuel pump is letting to much fuel in ?????
 

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sounds like not enough fuel. Adjust the idle up, maybe give the fuel screw a 1/4 turn in.
HOWEVER,
Pulling out the advance knob advances pump timing .20mm if it's working properly. I can't imagine why that would make it die, but double-check the timing - could be way off. .90mm is a good setting.

I'd also wonder if all the injectors are firing, gotta loosen the 17mm fuel line nut (at the injector) while it's running to see if there is NO change in the idle.
 

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Yep, over the years I found that Base timing of the Injection pump as in Belt replacement and the locking bolt will get you to the ball park, and the engine runs.
But using the dial gauge will get you right to your seat behind Home Plate.

I got so that after a few times with the Dial gauge, (over 20 years of dieselness) I could tell by ear on my running engine where it needed to be.
Also after a change, that you really need to be anal about bleeding the thing of all air. The Hardest for me was realizing that the Air was between the Pump and the Injector stand-offs on the Steel Manifold and once that I Cracked the Stand offs from the manifold and the weeped fuel, then a quick bleed of the injector lines and I had a purring engine. The clue was that I wasn't getting anything out of the injector pump to the fuel lines.... and I had no air bubbles in the Clear line.
 

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Discussion Starter #5
Since you are doing such a great job, I have one more question. In the Bentley Services Manual-electrical 6-54 fig 8-18 back up lite switch. Where does this wire come from. I thought I had everything hook-up but I missed this one some how. Thanks Allen
 

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Since you are doing such a great job, I have one more question. In the Bentley Services Manual-electrical 6-54 fig 8-18 back up lite switch. Where does this wire come from. I thought I had everything hook-up but I missed this one some how. Thanks Allen
Well the Bentley/Haynes I owned for that year wasn't a real 81, it was a 1980, and there are slight differences in the diagrams that weren't on my 81.

So I would refer you to the Chris's pages for a better description of the wiring as to where it comes from and goes to.
http://chris.chemidl.in/vw-wiring-diagram-pdf-1982-1983-1984/



Section 1 page 22 from the ignition switch through f12 back out the firewall to the tranny switch Gray/blue 18Ga, through the switch on the transmission out is black/green back to the backup lights.
 
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