Occasional Clanking after performance pump intstall

[levi20AE]

I got a new Giles pump for the AAZ motor in the truck and it was like heaven for a few blocks then i started getting a load metal on metal sound.  It really flew for those few blocks though     P.S. the boost never got above 10-12 PSI so i don't think i broke something.  The sound gets loader with RPM and increases in frequency. Its odd though cause the sound is not always present. I got the truck home pulled the valve cover and re-checked the timing to ensure it didnt jump a tooth or anything.  Sure enough, everything was still correctly timed and when i restarted the truck the sound was gone.   But as soon as i revved the motor it came back and eventually went away after idling for a bit.  I set the injection pump timing to .95mm per Vince Waldon's site for a Giles pump.  There is a little blue smoke from the exhaust when the clanking sound is present but when the sound is gone so is the smoke...  Could a clogged injector cause the symptoms? Is my pump timing way to off?  Thanks for any help. 

[levi20AE]

That's what I was hoping! Thanks, it did sound very much like what my 1.6TD sounded like when one of the hard lines failed, pretty scary.  Can i diagnose which injector by loosening one hard line at a time till the sound goes away?  I guess something small got in the hard lines while they sat on the shelf over night.  Does Giles increase the amount of pressure in the lines as a result of the modifications? I'm wondering if the injector was possibly on its last leg and the pump put it out of its misery.

[burn_your_money]

Increased fueling increases pressure, so yes Giles did increase the pressure. Most likely it's just a piece of dirt causing the injector to stick. You can test it by loosening injectors. Do it a few times to make sure that running on 3 cylinders doesn't temporarily clear up the noise leading to a false diagnoses.

[levi20AE]

So today I started loosening each hard line one at a time. It seems that by loosening any of the lines, most of the noise goes away aside from the idling getting much rougher.  Now i did notice that loosening #3 made the  most dramatic change in sound.  I'm going to call Giles tomorrow and see what he suggests for timing and get his thoughts.  Luckily there is a diesel shop in town that is a Bosch repair center so if an injector turns out to be the culprit it will be a quick turn around.

Does it make sense for the clanging to reduce when opening any of the injector lines??? That's the part that has me stumped.

[levi20AE]

Sure enough #3 failed open. Also the Bosch tech said the other three injectors looked very worn... Much more than the 55k that the motor was advertised.  Picking up new heat shields in the morning so hopefully will be up and running soon.

Update: got it running this morning and it performs amazingly.  Idle is much smoother and the power difference moving from an ECO pump to a Giles pump is very impressive.

[burn_your_money]

Glad to hear you got it sorted. Thanks for reporting back.

[levi20AE]

No, thank you for the info.  Really helped calm my fears I may have dorked something up real good.