Hi i've just read your thread start to finish and wow you have done an amazing job! You have a very straight and solid Mk2 i can't believe how well your engine bay turned out! It's a shame to see you've done all this hard work and had no reward as of yet. Trust me it will be well worth it when you get it sorted! Was it mis-firing in the ibiza at all? It might be a poor quality lead or bad plug. have you checked the plug gaps and colours? I know it sounds stupid but you have changed all the sensors to no avail and its not throwing up any fault codes any more (correct me if i'm wrong). It shouldn't be wiring related as you have had RJ do your wiring and when i did my ABF conversion i didnt have to modify any of the loom that goes to the engine sensors so in my mind it has a high chance of being a consumable that you changed whilst the engine was out, i.e lead or plugs etc. Just re read the bit where RJ took the loom and ECU to test it, i guess it tested fine and didn't cause any mis-firing on the engine he tested on?
Cheers for the heads up and comments Mine is definitely affected being just sat on the driveway but like yourself has a second hand dizzy in it. I might have to book it in for an MOT regardless so I can get it out on the street to test it under load. Wiring seems all good to be honest, checked all of the common ABF wiring faults and RJ has been through the loom twice for me lol Cheers, yeah it'll be worth it in the end, had this car a fair few years now, labour of love/bain of my life lol The Ibiza did have one fault where it would bog down and sometimes be hard to start. I put it down the crank sensor to be honest as the wiring for it was knackered! Certainly none of the misfiring problems, pulled like train! Had the plugs out a few times, brand new items and colours/gaps etc all seem normal but yes you are right I think it must be something I've renewed or something that's Golf related rather than Seat. Yeah RJ and Toyotec have kindly tested the ECU for me, no problems to report there and as Toyotec re calibrated it for me it's factory fresh bar the immob defeat. Update from the weekend: Put a new proper ISV on it to try to solve the idling issue. Had a choice of 2 ISV's and luckily one of them worked so that's one thing off of the list. I think we may finally be onto something too - fueling. When Eddie popped over he mentioned the car was running very lean. I was thinking about this the other day and how the car fires straight into life on the key but starts to misbehave soon after. I'm back thinking maybe the digi 8v pump isn't pushing enough fuel through to feed it, primes up fine so therefore starts fine but with a combination of low fuel level in the tank and an aged main pump perhaps the engine is being starved. I know this is something RJ has mentioned to me before too. On closer inspection I noticed a puddle of fuel on the garage floor and a pump which is looking pretty unhealthy: Definitely an area to investigate further.
I haven't seen a mention of injectors on here, which may be worth a look incase they need a clean. But, with your fuel pump & housing looking like it does, maybe you need a replacement. I do have a housing & pump with new seal & screws (they rust) in great condition sat in the garage if you need it. Digifant/G60 pump, which is fine for ABF
Looking good That weird soundproofing stuff on the first page thats like lots of little pouches filled with sand is factory, it was the same in my passat. It's cool stuff actually, absorbs sound by converting the vibrations of the sound waves into heat due to the friction of the grains rubbing against each other. Rolls royces etc. have little cups filled with the same stuff on chassis legs and subframes which do the same thing. Although they look really dodgy if they split as the grains inside are white lol I was a bit worried the first time I lifted the carpets.
if it was me i would put a k-jet pump on there or better yet mk3 setup, that way you know the pump is definitly providing enough fuel. in theory the digi 8v pumps are good enough if in tip top condition as they were used in the toledo abf, but id rather either go for a higher spec pump (k-jet) or newer pump (mk3) plus mk3 stuff is much easier to get in scrappy as loads of mk3s being scrapped these days. the tank, filter carrier and lines can come from any mk3 petrol, its just pump that needs to be gti, 16v or vr6
That creates extra work if the car was originally a Digifant 8V. Toyotec's "J0RAN" Mk2 ABF has the stock fuel pump & happily achieves 175PS with no issues.
At the time of my visit, JORAN had no 5th gear. If the weather calms down then I am happy to come back and have a closer look at the fuel system of your car and swap components over to JORAN until it can run like yours (crap). I can also come with the fuel pressure testing kit as well to confirm if the pump or fuel delivery system is at fault.
Good point on the injectors, the seals looked ok when I had the fuel rail off however the actual injectors could probably do with a clean. Can that be a DIY job or specialist? Cheers, yeah it's weird stuff. The Ibiza donor had odd rectangular plastic wrapped packages (cheapo insulation) which looked pretty dodgy stuffed in the wheel wells - there was a split second thought of 'WTF is this' when I stripped it all out lol Cheers John will have to do some research into it to see what I need. As you said before it's a worthwhile upgrade and it's the option that makes the most sense. I even have the ABF fuel pump from the beeza still. However I desperately want this on the road and was thinking about swapping the tank etc next winter when I plan to refurb the rear beam. K-jet is an option but that has different fittings IIRC? Are these all 4 bar? Scrappy might be a bit tricky as surely the cars will have all been depolluted (i.e hole in the tank)? Probs be able to the brackets etc though I'm tempted to just put another known good 8v digi one on there as a temp measure to see if it solves the problem, then upgrade in the winter. As above Cheers Eddie, that would be appreciated if you happen to have an afternoon spare sometime. Fuel pressure test would be beneficial. Would be very interested in seeing JORAN in the metal too
for the k-jet all you need to do is buy an m12x1.5 barbed adaptor off ebay and bin all the pipes + accumulator, fit a digifant fuel filter and that will convert it to digifant fitment something like this: http://www.ebay.co.uk/itm/M12x1-5-M...L-OIL-PUMP-HOSE-FITTING-ADAPTOR-/370609378089 trouble with digifant pump (and k-jet) is they're at least 22 years old now so you could end up in the same boat. at least with k-jet you have extra overhead spec wise! if you can find a brand new bosch digi pump then go for that, but you'll still need a plastic housing from vw by the looks of it as when they leak like that it tends to be because the plastic has split rather than the seal has gone. its not abnout them being under-spec, they were std on abf toledo as i already said plus early G60 even had them! its about mk3s beign easier to find in scrappies for the future, plus the pump design is much better with no under-car unit to corrode away like the mk2. you have pm anyway j
Right then, time for an update I think. Toyotec popped down from London yesterday armed with a fuel pressure test kit, his expertise, a spare fuel pump from Ben S and the infamous J0RAN his ABF'd Mk2 for testing. First on the agenda was to see what pressure the original 8v digi pump was putting out. Expecting a low result I was surprised to see Eddie was reading 3bar from it. Despite weeping under the car it appeared the actual output from the pump was all AOK. Tick that one from the list. Eddie pointed out an error I'd made during the fuel line installation which could well have been a contributing factor to the bad running. I'd pushed the ABF hose connections too far down the Mk2 lines and clamped a fuel clip down on the wrong part of the line as illustrated below (screw driver shows where I originally had it clamped). With that ticked off of the list it the car was still up to it's usual misfire tricks so next on the agenda was to swap components into J0RAN to see if the problem could be simulated there. Took out the BERU plugs from my engine and swapped in the NGK plugs from J0RAN and what do you know, one idling, smooth running ABF! To double check the plugs Eddie popped the BERU ones into J0RAN and we went for a spin. Christ that car can shift, the acceleration surge on it is brutal, and best of all it looks like a standard 8v, proper sleeper! Whilst I was busy grinning ear to ear Eddie tested the car at different speeds noting an all too familiar miss/hesitation at slow speeds. Interesting! Once back at the garage Eddie scanned the car with VAGCOM again to double check any faults, clearing this little lot from where we'd been unplugging various components giving the ABF a clean slate. SO, (I say this with slightly baited breath lol) it would appear that the running issues are now resolved! Will be swapping the fuel pump over sometime this week to cure the leak, small brake servo air leak to trace, put a few bits of trim back together and then it's MOT time again! Would just like to say a MASSIVE thanks to Eddie for coming down twice, testing components, tweaking the cars ECU and general expertise, Rubjonny, again for expansive knowledge, endless patience, making and testing my loom again and generally being a top chap and Ben S for sorting out the fuel pump for me - cheers guys, wouldn't be at this stage without your help or club spirit With any luck the car will be on the road in the next few weeks so can give it a proper roadtest to iron out any teething issues that may remain. Can't wait
That's great to hear its ready for MOT I hope to start getting my mk2 back together next month and get the ABF in to
Glad you finally seem to of got to the bottom of the problem!! That Toyotec certainly knows his stuff!!!! Look forward to hearing about how it performs on the road.
Cheers guys Made a bit more progress today, tidying up a few areas, putting trim back on etc but mainly focussed on swapping the new fuel pump over from Ben S. First up was to get the car up on stands and inspect the original on there. Looking pretty grim but all the clips came off with ease and I managed to avoid a face full of petrol which is always a bonus lol New lines and filter replaced: Fresh 10 litres of fuel in, pump primed, Job done Couple of new additions to the interior too - replacement red stitched gear boot as the old one was ripped and also a VW Motorsport gearknob. Undecided on this (looks a bit ripspeedy lol) but having it anodised black or something might help it look a bit more subtle perhaps. Also picked up an OMP Trecento 300mm at a good price from the bay of e. Need to grab a boss for it sometime but I reckon this will be pretty good to drive with It's also in great condition too (horn push sticker hasn't even been put on yet). Will be keeping the leather Rallye wheel still too though. Noticed today one of the CV boots has a slight tear in it so will need to address that asap too but not too bad a job. That's all for now.
lol Rather gutting but it seems the ABF's good health was short lived. Curse word misfire/cut out problem is back with vengeance Eddie has kindly been raiding his parts bin for other parts to try which has ruled out the TCI unit and today I tried another fuel rail/FPR/Injectors on it to see if that cured the problem. It's so odd, one minute it'll run from cold no problem but start to mess about when warm. Other time it just runs like **** from cold. Really hard to hold revs steady, they sort of bounce with a noticeable stutter at 2k rpm but it'll rev lovely and cleanly if you boot the accelerator. After cutting out sometimes it'll fire straight up again, others not until it's cool. Really scratching my head as to what I'm missing on this one but it's back to the drawing board! Ah ABF's are awesome...lol Vid of it titting about: Need to have a think about next steps.
Been a while since I've updated this thread and indeed been about on the forum to be honest, so for those interested a few developments. Quite a lot has happened over the past few months. Ed and Ben S popped down to have a look at the car a fair few months back (cheers again guys). Unfortunately after putting in a good few hours we were still all scratching our heads as to where the problem lay. I think we were all pretty disheartened but Ben took me out for a blast in his ABF'd Mk2 which helped boost my motivation again. Having had a taster of both the now deceased JORAN and Ben's MK2 I knew the conversion would be worth the hassle eventually but I just closed the garage door and left the car for a while. Over the last couple of months I can't really remember what order things went in but a trip to north wales saw this in the boot of my daily diseasal: A trip up to the infamous RJ for a trade in looms mean't I had a known good loom (cheers chap) A visit to the local breakers saw me massively in a luck as a complete Mk3 ABF had just come in which I salvaged pretty much any engine component from plus a whole other host of bits for a mates conversion. I did think about taking the whole engine but with unknown history I didn't risk it. The biggest bonus of this scrapyard find was the fact its an early car meaning a demobilised ECU. Pulled the whole lot out over the last bank holiday and put the new lump in: So with a new engine, new loom and various components tested...it still wouldn't run right. Arses. lol Having had a bit of a rethink I called on a mate who runs a workshop not too far from me to see what his thoughts were. As he's on a private estate it made sense to take the car over for a proper testing and for some fresh eyes to be cast on it. Towed it over one evening on a straight bar, left it with him and forgot about it. The next day I had a phonecall which went something along the lines of 'Jon, the cars running fine, been going for a few hours, happily driving it about'. A bit puzzled and sceptical by this I popped over at the weekend to take a look. Sure enough its like the problem never existed! I drove it round the estate for 2 house trying every possible thing to replicate the problem but nope running sweet as a nut! Feeling a bit cocky and seeing as theres an MOT station on the estate I threw it in for a test. Failed on a few minor things but an hours work saw a green sheet and a running ABF! I got the car back on my birthday which was pretty cool so on a rainy August day I took it for the first drive: So to summerise I'm baffled how the car appears to have rectified itself, no doubt the problem may arise again but for now at least I've done around 200 miles of trouble free motoring touch wood. For a few mates who don't believe its actually left the garage a few shots of it out on the road over the weekend: Loving the engine so far, the power delivery feels all in the top end of the rev range which makes for a great drive and its certainly a lot better in the mk2 than it was in the Beeza (having said that not a lot of that original donor car remains lol). The 8v gearbox on it feels nice and lively too, part of me is wishing I'd lightened the flywheel but that can be for another day. Next steps are to change the cambelt, sort the blowing manifold and just drive the damn thing. Want to get some of the cosmetics sorted and book it in for a bit of bodywork but may leave that until next year now seeing as I've missed most of the summer. That's all for now, thanks for reading.
