Author Topic: 1.6 mechanical block with 1.9 hydrolic cylinderhead.."V (Read 8288 times)

Powered by Spearco · « **Reply #30 on:** March 16, 2009, 11:26:09 am »

How much?
I know that the CR has been lowered because the cylinder head and a three notch head gasket.
The timming is @ .98. Double and triple checked that. When it finally started, I pulled out the advance lever and seemed to rattle a bit more?
Any Ideas? Is it the three notch or a combo of the HG and the head thats on there?

Help :oops:

zukgod1 · « **Reply #31 on:** March 16, 2009, 12:02:52 pm »

It's going to be hard to start regardless of the timing I fear.

I would try 1.05 for starters and go from there. I think it's going to be a bit pingy at idle but it should start.

Powered by Spearco · « **Reply #32 on:** March 16, 2009, 02:59:01 pm »

As far as the gasket size that was measured, I'd have to dig through my notes.
No air leaks to speak of. You can see that in the video I did.
I started it up this morning w/ lever pull out, no block heater, and fired right up but after 5 secs. it sputtered out and died. Smoke seemed less white and more grayish to black.

zukgod1 · « **Reply #33 on:** March 16, 2009, 03:29:33 pm »

If it's firing right up then dieing I don't think it's a timing issue.

Sounds like an air leak, pump issue.

Powered by Spearco · « **Reply #34 on:** March 16, 2009, 03:39:59 pm »

I kind of think it might be the pump, but once its warmed up it idles fine.
It does still smoke when warm but not as much. When throttled up, it stumbles and sputters but does rev. Just slow to react.

Powered by Spearco · « **Reply #35 on:** March 16, 2009, 06:54:18 pm »

Def. no air from filter to pump. I never removed the inlet line to the pump when I pulled it. Just at the filter. Bled the fuel system w/ vaccum untill no air was present. I just don't see how air could be the proplem here with this issue.

burn_your_money · « **Reply #36 on:** March 16, 2009, 09:36:33 pm »

You may want to try a set of good known stock injectors just to see.

Powered by Spearco · « **Reply #37 on:** March 17, 2009, 12:50:45 am »

I reset the timming to 1.05 and it starts and runs much better. No more stumbling and sputtering, only when light throttle is applied. Then it really smokes. When fully warmed up no problems at all.
I haven't found my notes as far as what the piston protrusion measured, but I do remember that it needed a three notch.

Is it likly that all the smoke is due to that the rings have yet to seat and that would cause the heavy smoking until it warmed up. Everything swelling up and making less blow-by and more compresion?

I do have a super pump that Giles built for me that I could swap out to verify that the pump is infact at fault. It was made for the dragster though. I'll have to contact him to see if it would work for this setup.

Powered by Spearco · « **Reply #38 on:** March 18, 2009, 12:36:59 am »

I've talked to one of the guys at the local diesel sevice shops and I told him about the running condition of my truck. He said that he's seen some pumps that the front main shaft seal would alow air to get past the seal and smoke like the dickins until warmed up.
Any thoughts or comments about this.

Also talked to Giles and he had recommended advancing the timming when cold until smoking is less.

Powered by Spearco · « **Reply #39 on:** April 04, 2009, 02:46:46 pm »

Update:
The main shaft seal was leaking/ sucking air into the pump. Fixed that, but had another TD pump rebuilt for another project.
Installed the new/ rebuilt pump on truck and set timming to 1.0mm
bled all air from lines and fired it up. Still smokes :evil: . No fire on #3 cylinder. Swaped #3 injector w/ #4 injector, but did a compression, and leak down tests. 425 psi and 0% leakage on #3 cylinder. Fasted up the injectors and lines. Bled air again and fired it up.
Still no fire on #3, even with the line cracked at 2K RPM. No fire :evil: :roll: . Swaped pumps thinking it was the pump and still no fire on #3. WTF!. Pulled the valve cover and found that some of the lifters were flat. #3 intake and #1 exhaust. Swaped out all lifters w/ new INA brand OEM one's. Bled down the new lifters 1/4 turn at a time to make sure no valves would hit. Hooked up oil psi gauge at head fired it up and still no fire on #3 cylinder! Oil psi is at 40 @ idle and 80 @ 2K RPM. All lifters are pumped up now but no fire. The hole time messing with it the block heater was plugged in and nice and warm to the touch.
How can it be that after all that it still won't fire?
Now that its cold from siting over night, I'll do a compression test to all cylinders. Then next ? Maybe pull the head and see if theres something wrong.

Any ideas as to whats wrong?

Thanks, Josh

Powered by Spearco · « **Reply #40 on:** April 04, 2009, 03:49:07 pm »

Pulled the cam out to check for flat lifters and busted valve springs, None. Compression is good. WTF. Could it be a cracked precup?
Anyone? Anything?

Powered by Spearco · « **Reply #41 on:** April 04, 2009, 04:19:52 pm »

Yes, glow plug is glowing good and hot. Yes, no change in RPM when injector line is cracked loose at idle or raised. Pulled out the injector to see if by chance if I could see a cracked precup, no luck so far.

Powered by Spearco · « **Reply #42 on:** April 04, 2009, 07:45:52 pm »

I pulled the head. Nothing to speak of for the problem, other than piston to cylinder clearance is very sloppy. No signs of cracked pistons or precup's. :? WTF! I'm going to pull the hole engine and send it back to the machineist and let him check it out. If you'ld ask me, it looks like to much piston slop on all cylinders. Mainly #3 cylinder.
I'll post some pics later. That is if anyone is interested in this :?

subsonic · « **Reply #43 on:** April 04, 2009, 11:06:33 pm »

Cant you flip the lines so they stick up in the air, attach the injectors and try it? I know it will make a god awful mess, but you will know for certain if you are getting fuel to #3. Just a late night idea.

Powered by Spearco · « **Reply #44 on:** April 05, 2009, 12:21:50 am »

Andrew, I did change to a good pump, and still the same condition. Changed injectors and lines, checked compression, leak tested, and changed to known good new lifters. A good visual at the springs, saw nothing unusual. I've got alot of money into this engine to not just pull the head and see if theres something, maybe by slight chance.
Well, I did and saw nothing right away.

I did see that there is alot of piston to cylinder clearance. I can shake the tops of the pistons with my gingers and does make noise. On all of them.
Looks like hole #2 is starting to make some contact with skirts and tops.
The head is beautiful as far as I can see.
I have to admit I screw up when origanaly measuring piston protrusion it was a three notch. Its supposed to be a one notch.
#1 .65mm
#2 .51mm
#3 .58mm
#4 .56mm
Is it possable for #3 to not fire due to PP and the sloppy pistons.
Not to mention, the 1.9 head.
I remember having a Rabbit or two that had three notch, when it should of had a one. ?
I'm going to pull the piston assemblies and measure them and check clearance's.