TD27 injector pump install

[navara nik]

Hi everyone,

New to Offroad express, thought it would be a great place to find info/tips on my new toy...

I recently bought my first 4x4, a 1996 D21 Navara. It's got a non turbo TD27 in it, which was running great and started first pop everytime. I quickly discovered it was lacking greatly in the power department. So I began sourcing parts for the addition of a Turbo.

Within a couple of weeks I had a turbo(similar size to a stock TD27T turbo), a TD27T Injector pump(dont want to be smoking excessively off boost), exhaust manifold and all other small bits and bobs required.

Monday this week I set about fitting the turbo injector pump, got everything removed and ready to fit the pump. Fitted and timed the pump to 0.59mm at 4 degrees BTDC. Bled the system with the pump on top of the filter, cracked the injectors then cranked engine and had plenty of diesel at injectors. Went to start the engine and this is where I got stuck.

Cranked the engine several times for about ten seconds each time. No sign of starting at all. Tried again about an hour later this time with abit of throttle, it fired after about 5 seconds cranking with huge amounts of white smoke out the exhaust, loud knocking sound at higher revs(not a normal diesel sound) and wouldn't idle. Adjusted the timing to retard it and it produced less smoke but still a bad knocking noise.

I've been adjusting the pump timing back and forth every night after work this week and I cant seem to get anywhere, always hard to start, white smoke and that bad knock.

I'm mechanically minded and have worked on all my vehicles.. Never a diesel though.. This one has me stumped and I need a hand figuring out what to do next..

The engine was running mint before I removed the old pump, no knocking,no smoke(only the normal black under hard acceleration)...

I would appreciate any help that could point me in the right direction.

Cheers

Nik

[slidenyo]

are you sure you had tdc when lining up the marks?
pulling the valve cover to make sure inlet and exhaust are shut on no.1 or removing a glowplug and dipping in a bit of wire may help
sounds 180 out to me?

[navara nik]

Yea I checked that yesterday and it was 180 out, re timed it(I'm guessing still not right) and still the same symptoms. Too frustrated now so I'll come back to it next week haha

[Crash bandicoot]

IF the TD27T i stripped the pump off to replace the ETI pump in my truck is anything to go by.... did you have the timing mark on the injector pump gear between the two marks on the drive gear? also i noted when I dismantled the engine at TDC the keyway on the pump gear was also at the top of the shaft.

[DIESELFIXNZ]

Hi if you are confident that your timing is correct i would check that you have got the firing order of the injector pipe correct also make sure that a injector isn't stuck open or fuel return isn't restricted causing injectors to hydraulic lock

[navara nik]

Thanks for the replies, I just realised I may not have the timing marks lined up, I set the pump to 0.59 at tdc but the pump won't be injecting the fuel into the right cylinder. Will have a go tomorrow, hopefully it solves it. Cheers

[ChurchurDan]

There are timing marks on the pump gear and the the gear that drives it, check they are lined up. They can be seen with the small front cover removed.

[navara nik]

Checked the timing marks and they were way off. Re-timed gears and set the pump to 0.59 at TDC. It runs like a clock! Only one thing, a little bit of white smoke at mid-higher revs e.g. 2000 and over.. Could this be because the turbo isn't fitted yet? Or could the timing now just a little retarted or advanced?

[Crash bandicoot]

could be a few things but i wouldn't tinker with it until she's got boost as the diaphragm needs the pressure to regulate the fuel.

white smoke denotes water either in the fuel or from the water jacket, glow plugs not working properly/unburnt fuel(no turbo yet)...most probable explanation

[navara nik]

Yea I was thinking that not having the boost could be the issue, I'll be chucking the turbo on during the week so we'll see what happens after that. Thanks a lot mate