Got another one! Project: PolarXJ

[xj_man_646]

Man...that sucks! What pump does that engine use in this configuration?

[TJTodd]

... at least you aren't fighting with a CP4 in a new Gladiator with the 3.0 ecodiesel?

[6DoF]

air bled ... IQ set ... everything else hooked up. alternator charges, n75 is in, MAP mounted, wiring tied up, and actually has way more pep driving than i thought it would!

still can't start it

seriously though ... i can bump start it, fires right up, but no amount of starter cranking will get it to even pop.

[xj_man_646]

That is a bizarre issue. Once its running, all is fine? What's the longest you've kept it running so far?

[6DoF]

once running, she's pretty great. just maybe a little bit of a rougher idle than i'd expect. last run i've driven it up n down the driveway a few time and even around the block. gets warm, defrost works, radiator hoses got warm, etc. no fuel leaks i can tell either.

at this point, the only guess i have, after some research, is that the pump is worn out. basically at the starting RPM, it can't make enough PSI to pop the new injectors. bump starting kicks it over less revolutions, but much faster, and as soon as one cylinder fires it's spinning fast enough to create the PSI.

i'm guna call a few shops today n ask around for thoughts. but now i'm torn between finding another junkyard pump or just getting a re-man.

[xj_man_646]

What pump is it?

[TJTodd]

if you are down to a replacement pump ... i'd say re-man vs another junkyard piece ... buy once, cry once

[xj_man_646]

I was going to suggest the opposite. With more complex components, OEM has usually lasted longer than re-man for me , even if they do come from a JY.

[TJTodd]

"OEM has usually lasted longer than re-man for me" ..... OEM yes, but junkyard has always been a gamble for me ..... I could just be chicken.

[6DoF]

pump is good! i wired the TDI ECU to a key-on wire that is fracking oooofffff during cranking! i can't believe i did that ... but i'd much rather swallow my pride on a stupid mistake than the bill for a rebuilt IP. new wire, instant BRAP!

drove it to buy it's own wiper blades, and that feels good. definitely has enough enough power, that's feels REALLY good. it's the Golf i always wished i had back in the day.

the drive shaft angles are junk right now from me just throwing it together, so they vibrate. i used poly engine mounts and the engine vibrates the chassis at a light more than i expected vs the old golf. plus something in the front axle isn't happy. something is binding, or grinding, or just worn out ... but jacked up and wigglin' everything it's all tight. i'll have to get deeper later. tonight's a win and i'm celebrating.

[nblehm]

that is 2 projects you have gotten running and I still dont have the waggy done

[6DoF]

Originally Posted by nblehm

that is 2 projects you have gotten running and I still dont have the waggy done

to be fair, you have a kid who seams to be pretty cool ... that's a big project! but yeah, wtf slacker, get on that waggy!

also, things drive sooner when you live by the Freiburger-ism ... "don't get it right, just get it running" if a family member was in the hospital, i'd blast this 80 down the freeway, but they aren't, and i was SERIOUSLY hesitant to drive it the 6miles to work this morning. there are so many different vibrations, rattles, and clunk noises that i can't even determine where to start

i need to plug the computer back in to check timing and mess with the IQ, see if i can't get the idle to smooth out some. i either need to play shim games on the rear axle or get the SYE. front axle needs adjustable uppers at minimum ... but i might need to cut the coils to loose some height with how light this engine is.

[xj_man_646]

That is awesome! Easy fix is best fix.

[6DoF]

after the drive to/from work yesterday, definitely need to work on some things. the idle is way too rough to be correct, and my drive shaft angles are super bad. but it runs!

i got back into the IQ and 'hammer mod' reset myself to 3.8-4.0, it only just kind of flips back n forth slowly. that seams pretty good, but it's still just shaking the crap out of the jeep. smooth while cruising though, so I'm hopefully it's something like a timing adjustment in VCDS that i just haven't figure out how to do yet.

building this i put the engine in where it fit the best, and just blindly swapped the lift kit on quick so i could move it around. now that it's running, it's time to go back and tune in the drive shaft angles. measured last night and I'm 13deg out in the back and 16deg out in the front!

[Cobound]

You people's patience is amazing

Nate, you have as many hours wheeling that Willys as he has working on this XJ - both cool!

[TJTodd]

I'd suggest sitting at a few red lights for a while with a well endowed female passenger before you get that fixed ;-)

[6DoF]

[Cobound]

Not sure that is a good example...

[TJTodd]

yeah ... was thinking more like this .....

[6DoF]

now that's how you start a new page!

big improvements happened:
-front diff was low, topped off with 85-140 diff honey
-rear diff was over full but thin ... siphoned some and re-filled with diff honey
-front drive shaft removed
-rear drive shaft replaced 2 caps to the joint is tight at the axle
-track bar bolt was falling out ... reinstalled with nut this time
-greased all TRE and Ball joints
-drained strawberry milkshake from the t-case ... refilled with MTF and some trany honey
-reset the IQ in the TDI ECU to slightly smooth the idle some

still need to check all timing mechanical vs digital is aligned in the ECU, but i need a paid copy of the VCDS first. working on that. rear shaft still vibrates, but in general the whole thing is WAY better!!

ordered a new steering stabilizer, adjustable front UCAs, and an SYE. should be dialed in no time.

i'm also fairly sure i'm going to cut the front coils down by like 1" cuz this motor is so freaking light. the front is taller than the back, and i added lift shackles to the back over the kit.