Very rough running

[RunninWild]

I was just about to go to sleep when I thought of something. Is there any difference in the amount of throw or anything between an aaz pump and a 1.6td pump throttle? When I installed this pump my throttle cable was super tight and holding the throttle open a bit. I had to adjust it at my pedal. I'm wondering if maybe how it was originally adjusted was proper and maybe the pump is pushing it too far back? I don't know if this is making any sense I'm tired lol. Does anyone else with an aaz pump have a preload on the throttle?  But if that was the case then the idle screw would have no effect. It has to be off a tooth eh?

[Tylenol]

How much did you screw in the fuel screw on the pump for it to run or you still running it like this? I think your trying to fix more things then you should at once. Do the linkage to shaft adjustment then put your fuel screw back where it was get your injectors fixed or calibrated. Sounds like your trying to make it run but not fixing any of the problems you know you have!

[RunninWild]

Yeah I think your right I'm just stressing out and my head is all over the place. I'm going to play with the timing after work and I'll try and find some torx bits to get the throttle adjusted.

[vanbcguy]

I missed until now that you have an AAZ head on a 1.6. That is DEFINITELY a recipe for white smoke when the engine is cold due to low compression.

[RunninWild]

Yeah but it still smokes when it's warm. Have a look at the 12nd video I posted that's when warmed up

[burn_your_money]

I really would suggest not messing with the pump until you are sure it's nothing else. This isn't an error that I can see making it out of the shop.

Where are you located? You can usually get injectors tested for free or like $10. I think a Giles rebuilt set is under $200 but it's been a few years since I've seen a price.

If the injector is dribbling fuel that will cause smoke, and serious engine damage as well.

[ORCoaster]

RunninWild,  Take a deep breath.  Exhale. 


I would be looking at a local diesel shop to rebuild the injectors you have or as suggested have them pop tested.  They all should spray out at the pressure written on the side of the body.  Wild fluctuations between high and low are not good. 

There are several threads within this forum that will adequately describe how to reform a heat shield for reuse.  I use a ball bearing, a pair of vice grips and a sleeve out of my compression tester kit.  How you would love to have that right about now. 
 
The hoses on the nipples of the injectors returns the excess fuel, that's right not all of it gets delivered to the cylinder, to the outbolt and then to the fuel tank.  Having good lines on them keeps the engine clean mostly.  But you can see air passing between cylinders if the line is clean.  Motorcycle fuel line can work on these and is probably available at a local shop, it is clear.

With the swap you have going, the potential for a headgasket being more than you need and the questionable timing here You just need to focus on one at a time to make it right and get it off the list of possibles.  So, breathe in breathe out.

Just don't stand next to that running rig of yours.  cough cough.
 

[RunninWild]

Yeah I think I'm going to order a set this weekend. I'll email Giles and see what he says I don't know if my aaz injectors are rebuildable as one of the nipples broke off and I welded it so it wouldn't leak but the 2nd nipple ended up leaking as well so it's probably garbage. Does he sell rebuilt injectors without a core?

I agree it's weird it would come out of his shop misadjusted but at the same time I don't get how it has 0 effect on the idle speed. Stumbling or choking or even stalling would mean something. The lack of any difference to me at least only makes sense being misadjusted as no extra fuel is being introduced.

But the battery was dead this morning 😡 so won't be able to play with it for a couple days until I can borrow a charger again

[RunninWild]

Thanks orcoaster I think I needed that. I'm going to talk to my buddy and see if I can store it at his place then send my injectors off to get rebuilt. I live in whistler and there arnt any diesel specialist shops here and I can't see any of the normal shops having flow testers or even pop testers. The closest place would probably be in Vancouver but I'd have to drive there and I don't trust the truck to make a 2 hour trip in its current condition. Also the last time I looked into getting some injectors flow tested a shop in Vancouver wanted something stupid like $80 an injector or somewhere around there.

I'll email Giles now and see what he says about getting mine tested and rebuilt.

I'll also look into getting a compression tester from Amazon. Maybe I could do the old buy and return.

[vanbcguy]

Where are you located anyhow?

[vanbcguy]

Oh also - do you have power connected up to the timing lockout solenoid I see on your pump in the earlier pictures?

[burn_your_money]

Giles sells nipple replacements. I think we did it once while I worked there.

Idle is controlled by a different lever on the AAZ, not the throttle lever. I'm not saying that it's definitely not the throttle lever being off a spline, I'm just saying it's a pretty low chance since the pump does appear to be freshly rebuilt. There are a lot of more likely causes at this point and messing with the pump is just going to add more variables.

[RunninWild]

I live in Whistler Vanbcguy. Your welcome to come for a visit and give some advice 😘. I have a brewery right across the street from my place and I'll buy the first round! Plus I'd love to see your crazy electronic controlled aaz.

No I havnt hooked that up yet. I now it won't advance the timing but at the moment I think I have more issues to deal with then dynamic timing advance. It actually doesn't run that bad it's just the smoke, starting issues and odd idle.

On the plus side I found some used aaz injectors that supposedly ran fine before the engine was pulled I'm going to be ordering on Friday. I also found a good deal on a compression tester at kmstools I'll also be ordering. Between the new injectors and the compression tester I should have a better idea of what's going on with it.
I'm going to park the truck in the back yard and hopefully do some work to it I've been putting off. Shackle lift, finish the exhaust and maybe have a go at replacing that oil pan (got a pretty bad leak at the moment). The weather is getting cold and I need to get that stuff sorted before the snow falls. Plus it'll give me a break from the engine headache.

I'm going to take a break on the engine until the injectors and compression tester get here. I agree with trying to minimise the variables and don't want to make it even harder to diagnose. I've emailed Giles I'll see if he gets back to me. If not I'll probably just go with the used injectors.

Should 1.6td have any problems with the aaz pump burn? I know they are single stage with different pop pressures and I'm wondering if that could effect anything?

[vanbcguy]

Ah, I could see the Shaw IP address so figured you weren't too far. Still a pretty long haul though.

You're correct, the advance lockout won't do much of anything at idle, though it definitely will cause issues at higher RPMs.

The AAZ pump should be fine on the 1.6, I believe Giles actually uses the AAZ camplate for his super pumps. Nothing wrong there.

Hey so do you have a picture of the cold start side of the pump? You said you changes something there?

[RustyCaddy]

Sounds like you have a lot of $ laid out already but you can make a pop-tester using a porta-power relatively cheap and easily, not much more than the price quoted you for flow testing a single injector. Good for piece of mind, you know what you got and know when you have rebuilt the injector right. If you plan on keeping the diesel for a few many years and you can always sell the pop-tester when you no longer need it.  0.02