1991 TD42 diesel pump

[rlaxton]

Hi All,

I recently got my engine back from being rebuilt and everything is back together but I have realised that I am not entirely certain about where the various fuel rails go. They are OK at the injector end because I labelled each line but I may have something wrong at the other end. The engine is a little hard to start and when even a little accelerator is used the engine pings quite badly. I have tried the full range of static timing available by rotating the pump back and forth and the pump definitely lines up with the timing marks correctly.

Can someone give me the cylinder number of each of the ports on the back of the pump? They are in a circle.

Thanks,

Richard.

[ZAPPAGQ]

You may find that the rails are ok, maybe you should have a look at the injectors. Had a mate who rebuilt his cruiser and was doin the same thing. May have something to do with being a fresh motor(compression)

[rlaxton]

Thanks ZAPPAGQ, but I don't think so in this case. Since this is a fully reconditioned engine I also had the injectors done and the pump fully rebuilt with added boost compensator. I have it booked in at AG Diesel for Monday so we will see what it up.

Richard.

[GutSquisher Media]

Sounds more like the pump timing is out, if the pipes where wrong you would end up with more of a missfire or a load knocking sound.

Remember the pump needs to be static timed to 6 degrees. there are two timings marks on the belt wheels make sure your using the right one (second mark if I remember right).

[Woop]

Hard starting particularly after a re-build can be caused by low compression while new rings bed in. Make sure tappet clearances are set properly and injection pump timing is correct. I advanced my pump timing from the factory mark (0.35mm plunger lift@TDC) to 0.75mm=6degbtdc (fact manual setting) after my re-build, and i found this made starting much easier when cold. Only do this if you have a dial guage and adaptor to fit the pump and know what your doing. The injection pump pipes are laid out as follows: 'A' to CYL 1,'B' to CYL 4, 'C' to cyl 2, 'D' to cyl 6,'E' to cyl 3, 'F' to cyl 5. The letters corresponding to pump outlets are engraved next to the outlets on the pump and go anti-clockwise when looking at the back of the pump with A being top right oulet when looking at the back of the pump.

Nick

[rlaxton]

Hard starting particularly after a re-build can be caused by low compression while new rings bed in. Make sure tappet clearances are set properly and injection pump timing is correct. I advanced my pump timing from the factory mark (0.35mm plunger lift@TDC) to 0.75mm=6degbtdc (fact manual setting) after my re-build, and i found this made starting much easier when cold. Only do this if you have a dial guage and adaptor to fit the pump and know what your doing. The injection pump pipes are laid out as follows: 'A' to CYL 1,'B' to CYL 4, 'C' to cyl 2, 'D' to cyl 6,'E' to cyl 3, 'F' to cyl 5. The letters corresponding to pump outlets are engraved next to the outlets on the pump and go anti-clockwise when looking at the back of the pump with A being top right oulet when looking at the back of the pump.

Nick

Nick, that is just what the doctor ordered... Thanks! I will check tomorrow to verify that I did it as you state. I noticed the letters when I put the lines on but since the pump was caked with a mix of leaked diesel and mud when it was taken off, I did notice them earlier :-)

I am not overly worried about the hard starting at this point since as you said, the compression at the moment would be piss poor. My biggest worry was running out of run time to bed in the rings before I got the fuel system worked out.

Richard.

[rlaxton]

After going through Nick's port - cylinder table I found that I had switched 5 and 6 around! Once the switch was made everything was hunky-dory. Engine is now bedded in and ready to start running in.

Richard.