a little help please

[fixer941]

Hi, i'll keep this short to begin.
After breaking a piston i have put a rebuilt motor in, bench tested the injector pump (passed), new injectors, boost sensor and turbo, the truck seems to come on boost and run sweetly in 1st, 2nd and 3rd, starts running rich and blowing black smoke and running out of legs in 4th then in 5th am blowing steady black smoke and cant get it over 90kmh, any ideas on where to begin? The turbo was an aftermarket cheap chinese job, maybe its not up to the task?
T.I.A. Toby.

 

[fixer941]

Sorry, should have mentioned that its a zd30 in an 04 d22

 

[tony d22]

Injector pump might need tuning, a diesel mechanic should set things right.

 

[fixer941]

Thanks tony, from my understanding its tune is controlled by the ecu and because its not common rail that it cant be tuned would this be correct?

 

[tweak'e]

sounds more like typical neutral switch fault.

 

[Old.Tony]

I'd be wondering about the neutral position switch as well. Just disconnect it for a test drive. You'll need it connected so that you can engage 4LO if needed, so if that is the problem, it'll need replacing.

And welcome to the forum!

 

[Krankin]

Agreed......try the NPS first.

 

[fixer941]

Thanks guys, i just tested the nps using the heat switch method but it seems to be working fine (revs drop when selecting any gear) is this test considered reliable enough?

 

[Krankin]

what about driving with it disconnected.

 

[fixer941]

Havent tried that yet, i'll give it a go in the morning when i can see what i am doing

 

[fixer941]

so here goes reviving on old problem.

still no luck, ive sent the car to a diesel fuel specialist and after 2 months still no luck.

they have checked the turbo, waste gate, injectors, injector pump, neutral position switch, ecu, cat and exhaust, maf sensor, and had it on the dyno a dozen times.

the air/fuel ratio is good, injector grounding patterns check out but still it is 16kw down and pouring black smoke.

any other ideas from the guys that know the zd30's?

 

[nathand22]

I'd be wondering about the neutral position switch as well. Just disconnect it for a test drive. You'll need it connected so that you can engage 4LO if needed, so if that is the problem, it'll need replacing.

And welcome to the forum!

Tony, with my D22 i disconnected the NPS and just left it that way and i never had a prob selecting 4LO. The switch went before 100k and as you know the ute drowned with over 350k, and i never missed not having that switch even when the ute looked like this..... Half frozen

 

[nathand22]

so here goes reviving on old problem.

still no luck, ive sent the car to a diesel fuel specialist and after 2 months still no luck.

they have checked the turbo, waste gate, injectors, injector pump, neutral position switch, ecu, cat and exhaust, maf sensor, and had it on the dyno a dozen times.

the air/fuel ratio is good, injector grounding patterns check out but still it is 16kw down and pouring black smoke.

any other ideas from the guys that know the zd30's?

If it is poring black smoke it is over fuelling. Seems like the ECU is telling the pump to deliver the wrong amount of fuel, why?? i have no clue.....
Any chance you know someone that is willing to let you try plugging there Ecu into your Car just for a test???

 

[tweak'e]

the air/fuel ratio is good, injector grounding patterns check out but still it is 16kw down and pouring black smoke.

how the F can the A/F be good when its blowing out loads of smoke ??

i don't think its overfueling by ecu etc, its sounds like its lacking airflow. which makes me thing its valve related. either cam timing is out, valve clearances incorrect, swirl valve staying shut, something stuck in the intake manifold.

the other thing is egr is stuck open, block it off!

really need to know what the boost is doing and egt's.
A/F info would be good but you would need it pre cat which is difficult.

 

[fixer941]

thanks nathand22 it has had an ecu swap without making any difference

tweak'e that was the question i asked the mechanics myself and they had no answer for me all they could say was that the dyno and computer and sniffer says that everything is working fine. the timing has been checked by the guys who installed the motor and they provided photos then checked again by the fuel guys via the injector pump module and they both tell me that its not timing.
i will have the guys check the valve clearance and test the swirl valve and check the intake manifold.

if i block the egr do i need to run a pyro gauge?

i will try to get a print of the dyno sheet next time it goes on and post that but i believe that the a/f is done via a sniffer in the back though i could be wrong.

thanks heaps for all your help guys, i really do appreciate it.

 

[Old.Tony]

Blocking the EGR won't send the EGTs skyrocketing. The EGR valve is closed at full throttle anyway.

I agree with the other guys - the A/F mix is NOT ideal if it's belching smoke. If the fuel system is operating properly, then it's the air system - an intake restriction, an airflow sensor .... who knows. One guy that rocked up at my local dealer with a car that wouldn't run very well had the mechanics scratching their heads until they noticed that the grille over the snorkel intake was broken. Further investigation revealed that an owl had been hit and sucked down the tube where it blocked the intake at the elbow in the guard - very hard to see.

You might also (just for a test) disconnect the PCV hose from the air intake and see what happens. If the smoke all goes away, you may find that the gaps in your piston rings have aligned, or the rings are worn and you're getting significantly increased blow-by = extra EGR.

 

[Dave]

Whats the turbo boosting to max ?

 

[fixer941]

Hi guys, well i've asked them to check for air restrictions pre and post turbo and to do a compression test which for the record was the first thing they were asked to do by the mechanics who sent it to them and all i get is lines about how they are checking everything and that they know what they are doing, despite having had the car for 9 weeks without finding the problem, they said the turbo is "within factory specs" yet when pressed could not actually tell me what those specs were.
They have now just told me that its on the bottom of their list of priorities and wont be getting back to look at it fir at least 3 weeks and if i dont like that then i am more than welcome to take the car away because they are losing money on it, a thought i entertained untill i found out that all the other mechanics for miles around simply pull all the fuel parts off and send them to the guys who have it now to have them tested.
The only other ppl around who are specialists in diesel fuel have already told the original mechanics that they dont want to know about it.

So the long and the short of it is that the only guys who can do it cant be botheted with it any more and are probably quite annoyed at looking inept thus have put it in the too hard basket hoping i'll get the shits and take it away. F.M.L

 

[tweak'e]

sounds like they have no idea what they are doing.

get it back and start doing it yourself.

 

[fixer941]

Well it seems i shook the tree a little and i now have it sitting in the driveway, went down to have a word with the managing director and when i pulled up it was on the dyno with said MD and another under the bonnet putting an egr blanking plate in, hung around for the dyno run and found it was blowing very little smoke and gained 5kw, the smoke has gone from a steady stream down to an occasional little puff at WOT.

Drove it home and it seemed just like it was before the whole hand grenade thing, still 11kw down from factory spec however, its now got the egr block and the cat pulled out and running a straight through.

Any ideas on what its problem is?