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over fueling and my fault !

six pot

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Nov 22, 2014
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great_britain
Hi
I'm new to this forum but thought I might get the help I need. I have an 94 80 series, had it for about ten years. 2 inch lift, Old man emu suspension, Arb bumper, 285 75's ext. I tend to do most of the work myself as I find it cheaper but above all rewarding. Its a 4.2 six pot but normally aspirated, yes a little down on power but off road its torque characteristics are lovely and smooth.

The problem started with a small diesel leak in the seal on the lid of the injector pump, just behind the fuel in banjo bolt.
1/ moved the power steering reservoir out the way.
2/ disconnected the throttle linkage.
3/ removed the two pipes from the overflow banjo bolt.
4/ removed the four cap screws
5/ lift off the lid.

In lifting off the lid I had to move it back to release the internal spring that attaches to the control lever shaft, all good so far. The repaire of the seal was easy, but. In order to refit it is necessary to winde out the full load adjusting screw. This was ok as it was marked with bright yellow enamel paint, for reference. Then I did something silly, I removed the control lever shaft, with out marking it first. The exterior aspect of the shaft is splined to fit the control lever.

The reassembly went well and the diesel leak is no more. Groovy me thinks, lets try to start it. unfortunately it failed to fire, unless I give it about half throttle. So what I did is undo the throttle tick over lock nut and wind in the the tick over screw, then I would wind out the full load adjusting screw. insidently the paint came off. After a bit of this it was apparent that I would need to wind the tick over screw in quite a bit. In the end the result was great, cold start, hot start, tick over and rev up and down all good.

I decided to road test it, up hill. Now the problems begin. Under load it smoked black cash from the tail pipe like never befor. I should say in all the years this has never happened before. I thought too much fuel, so I wind out the full load adjusting screw a bit more ... and of course the tick over dropped a little so I compensated with the tick over adjusting screw, road test No.2. Things look better, or at least I can see the road behind me. I returned home and repeated the process several times, each time with an improvement to the over fuel. I then realised I was going to run out of adjustment on the tick over screw befor I got to where I needed to be.

My thought is that when refitting the control lever to the shaft, I fitted it out of whack to the internal spring carrying lever. I have looked for refs to the location of the top control lever in relation to the lower but alas nothing. I should be able to work this out for myself but I'm tired and perhaps I've been looking at it for too long. Tomorrow is another day as yet unspoilt by my antics.

Any who if you have had the time to read this and recognise the problem and perhaps even have some words of wisdom and experience then greatly appreciated.
 
You must have the 1HZ engine? To my knowledge there aren't that many owner's of them on here. If no one comes forth with the info you need, you're best bet may be to contact a few diesel specialists and hopefully find one who is familiar with the IP on the 1HZ engine. They should know the baseline settings for the pump and hopefully help you out or set it up for you, for a fee obviously. Assuming they don't have to strip and rebuild the IP I can't imagine it being too expensive.
 
Thank you for your responses, I think if I follow reason then if I mark the control lever and spline, then remove the control lever and rotate I should be able to pick up the slack I have had to tack up with the tick over screw. Or at least thats the theory. Patients and a steady hand.
 
Well I've done it, had a lot of fun too. These big normally aspirated diesels are so simple and a delight to work on.
 
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