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GTI K-Jet Runs for a few seconds then dies unless I hold ignition in starter position

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Been battling with this problem for a few weeks now and had some help from the guys on Facebook but still no joy so desperate measures I'm posting on here as well in hope.

Background I had a TSR built DX engine which the main pulley woodruff key sheered on and ended up bending the valves. After being quoted £800 to rebuild the head I decided to do this on the bench myself in my own time and in the meantime picked up another 1800DX with all the ancillaries from a guy who was doing a 20v conversion.

So I swapped the engines over and when I try to start it fires straight away runs for a few second then dies.  If I hold the key in the starter position so the starter motor is spinning the car continues to run as long as I hold it there (basically running off 5th injector).

So I hard wired the fuel pump by running a live to the pump and same problem.

Checked the power at the fuel regulator and there wasn't much so I put a perm live to it and it triggers the fuel pump is that a recognized way of getting the pump to run?
Anyway that didn't make any difference.  So I swapped the regulator over from my original engine still only 5 seconds of running.

Next I pulled the injectors fired the pump using live to regulator plug again and a magnet on the plunger and nothing coming out of injector, so removed injector and checked fuel was coming through the fuel line and it was.  This was the same for all 4 injectors.. very hopeful at this point this was my issue.

So replaced all injectors with an old set which I had ultrasonically cleaned..  Retested and they were all giving a nice mist of fuel into my jam jar.  With hopes high this was the issue it fired up for a few more seconds than normal and died again grrrrr tried a few times and same issue run for a few seconds and dies or runs fine with ignition in starter position…  then phone call from wife put an end to the evening as I was being too noisy.. not sure if she was referring to the engine noise or my swearing/kicking the car/hitting it with a branch

Any help or suggestions greatly appreciated. .. 1 suggestion was to run a live to the coil but wasn't sure if I should run it to 1 or 15 terminal on the coil?


 

1983 Lhasa Green Campaign 1800 DX K-Jet Engine
1971 VW Type 2 Devon Camper (muchos mods)
1973 VW Type 2 Westfalia Camper (standard)
 

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What year car do you have and is it a tin top or cabriolet?

What fuse box do you have, early type with bullet fuses or later type with blade fuses?
 


1988 Mk1 Golf GTi Cabriolet 1.8cc DX, K-jet. Daily drive. 317,000 miles and counting
1978 Mk1 Scirocco GLS 1.6cc FR, Webber carb. Weekend toy.

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Its a 1983 Campaign, Tin top with blade fuses.

Thanks

1983 Lhasa Green Campaign 1800 DX K-Jet Engine
1971 VW Type 2 Devon Camper (muchos mods)
1973 VW Type 2 Westfalia Camper (standard)
 

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So I believe there is no lift pump in the tank?
If you remove the back seat and the black round cover, if you have 3 wires going to the fuel tank you have a lift pump and if only 2 wires no lift pump.

Do you hear the fuel pump run when the car runs.

If you remove the fuel pump relay and remove the relay below it, turn the relay round so it fits in the fuel pump relay slot and when you turn the ignition on the fuel pump will run without the engine running, other method is remove the fuel pump relay and bridge the 2 larger connection with a chunky bit of wire and the fuel pump will run even without the key in.

Other thing to look at is possibly the ignition key switch as they wear when you have a large bunch of keys hanging from the, you can remove the lower cowling to gain access to the switch to test.
Search on here for ways to test the switch.

I just noticed you state what car you have in your signature  :$

1988 Mk1 Golf GTi Cabriolet 1.8cc DX, K-jet. Daily drive. 317,000 miles and counting
1978 Mk1 Scirocco GLS 1.6cc FR, Webber carb. Weekend toy.

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Thanks for that I'll give the relay swap a go tonight and check for a lift pump. I can't really hear the pump when engine is running due to the engine noise but when it stalls I can here it buzz for a second or so (I assume its the noise is the fuel pump that's buzzing).

You can remove the red cheeked emoji… I added car details to the signature after your question and seeing your signature :)

thanks

1983 Lhasa Green Campaign 1800 DX K-Jet Engine
1971 VW Type 2 Devon Camper (muchos mods)
1973 VW Type 2 Westfalia Camper (standard)
 

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Another thought… to see if you are right and it is just running on the 5th injector, what happens if you unplug the blue electrical connector on the 5th injector?

I guess it wont run at all?

1988 Mk1 Golf GTi Cabriolet 1.8cc DX, K-jet. Daily drive. 317,000 miles and counting
1978 Mk1 Scirocco GLS 1.6cc FR, Webber carb. Weekend toy.

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Correct it won't run without 5th injector plugged in.

1983 Lhasa Green Campaign 1800 DX K-Jet Engine
1971 VW Type 2 Devon Camper (muchos mods)
1973 VW Type 2 Westfalia Camper (standard)
 

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I'm wondering if the mixture is set too lean and it isn't moving the plunger when on idle so no fuel is getting through the injectors. If you give it some throttle does it rev or stay running? When I got my 1.8 GTI going last year I found the best way to get the mixture close enough to get it started was to fit the bypass relay so the fuel pump is running with the ignition, remove the injectors and put them in a jam jar, turn on the ignition and richen the mixture until fuel comes out of the injectors with the plunger in it's resting position and then turn it the other way until the fuel just stops coming out. When I did that the engine fired up and run well enough to start tweaking things.
I'm not familiar with a TSR so I don't know what bits are from the new engine and what bits are from the TSR but if the metering head has been left with fuel in for a long period of time it may need cleaning out.
Good luck, keep us posted.

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Thanks for the reply and sounds like a plan…  I have had some joy in that it now runs when I pump the accelerator or keep the revs really high.  So it sounds like it was probably the blocked injectors I just didnt get a chance to give it a good go before the wife shut me down for the night.  

So basically I need to get it tuned up now and your plan above sounds like it might be a good starting point for the fueling side of things. 

Cheers

1983 Lhasa Green Campaign 1800 DX K-Jet Engine
1971 VW Type 2 Devon Camper (muchos mods)
1973 VW Type 2 Westfalia Camper (standard)
 
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