runaway on 1st startup

[silvertdvw]

just fully rebuilt my 1.6td(rebore, pistons, rings etc.) and i tried to start it and it wants to run away
its like its at WOT when i try to start it up. the smoke out the exhaust smells like diesel, not oil and i've already tried backing the max fuel screw waay out.
While i had the injection pump out i changed the big seal that seals the steel end piece to the aluminum housing and the cold start o-ring, could i have screwed something up internally??
Also the injectors are newly rebuilt.

  HELP!!!!!!!!!!!!!!

[Vincent Waldon]

When you had the IP off to reseal it did you remove the throttle lever? 

If you turn the key off does the engine stop?

[honda_is_the_best]

the control collar probably came disconnected from the governor fulcrum plate. not sure what both of those pieces are actually called, but someone will chime in with the correct terms.

there is a very big chance that you re-sealing the pump has alot to do with the run-away. does the key kill it? if it does, then its not running away.

darn it vince, i was hoping you would post after me so you could make the corrections to the pieces i was talkin about  

you were quicker to the save button tho, by a few seconds.

[silvertdvw]

no i didn't have the throttle lever off and yes the key turns it off

[Vincent Waldon]

Here's a couple of pictures that may help:





So as our Honda friend says, most likely an issue with the control sleeve, since that's what slides along the plunger shaft and meters the fuel.  If the pump was inverted it may have slid down and jammed, the return spring may have become disconnected, etc.  If everything's nice and clean you can pull the lid of the pump off with the pump still in the car and have a look.

Did you completely remove the high pressure end of the pump to replace the o-ring, or just slide it out far enough to do the job?

[silvertdvw]

I pulled the end completely off the pump, so i guess i'm pulling it off again. Thanks for the fast replys and the diagrams.

[Vincent Waldon]

No worries... my interwebs guess is that you're going to find the control sleeve popped out of the little ball that attaches it to the control lever and is sliding freely on the plunger shaft... but that's just an interwebs guess.   

[silvertdvw]

i pulled the pump apart again and ball was not connected properly, so i fixed that and now i get absolutely no fuel  . The pump is fully primed and the selenoid is in working order, but no fuel comes out of the pump at all. what did i do now 

[maxfax]

Did you screw the fuel screw back?

[silvertdvw]

yes i screwed the fuel screw back to its original postion. It seems im not the only one with this problem http://www.vwdiesel.net/forum/index.php?topic=26624.0 too bad its also unresloved 

the pump was in working order before i pulled it apart to change the seals and i had fuel out of the delivery valves when the control sleve was not connected properly

[Vincent Waldon]

the pump was in working order before i pulled it apart to change the seals

Unfortunately I don't think there's much more we can suggest, other than pull it apart and see if you can figure out what's disconnected this time.  Sometimes the lever with the ball (that connects to the control sleeve) can jam a bit, sometimes the spring that pulls the lever back becomes disconnected, sometimes the throttle linkage itself unhooks. 

If you pop the lid off the top of the pump you should be able to confirm proper operation of all of the above and/or see if any of them are the issue.

[kingler5]

i pulled the pump apart again and ball was not connected properly, so i fixed that and now i get absolutely no fuel  . The pump is fully primed and the selenoid is in working order, but no fuel comes out of the pump at all. what did i do now 

I have done the exact same thing you did, and have the same problem right now, hopeful to find a solution, otherwise I'm sending this pump off to Giles.

[silvertdvw]

sometimes the spring that pulls the lever back becomes disconnected,

i pulled the top cover off and this spring is MIA now i just need to find it

[R.O.R-2.0]

spring that pulls the lever back? you mean the governor springs?

[silvertdvw]

picked up a used pump and the car is running great