6.5 new injection pump - losta smoke

[Sando]

I've only just discovered this site and am certainly impressed at the depth of knowledge out there. I've got a problem that I can't find to many leads on through searching the past posts. I'm hoping someone could shed some light on this please.
We put a new injection pump, injectors and glow plugs in a 98 pickup that was getting fairly tired and kept stopping etc. The stopping part has had some light shed on it since I found this forum but thats another story. I basically just unbolted the old parts and replaced with new.
The engine will now start, fires on the first crank, then runs about as rough as any engine could and is immediately the best white/grey smoke generator ever made.
I am fairly confident there is no air in the fuel. We have checked and checked. Rotating the pump as in timing adjustment doesn't seem to have a whole lot of effect on how smooth the engine runs. All the wires on the new pump all plugged back in to matching plugs so I don't think we got any of them wrong. The thing ran OK before we pulled it apart and whilst it doesn't say much for our mechanical abilities I keep thinking that there is something fairly straightforward that we have missed.
Any help would be greatly appreciated.

Cheers, Sando

[DennisG01]

Well, it sounds like you're more adapt on working on these engines than I am, but I'll just add one thing that I've picked up on this site over the years.

Does the white smoke eventually go away? How long did you run the engine? White smoke is usually due to a cold engine/non-working glow system. Replacing plugs is good, but are you sure you're getting power to the plugs during the start-up and warm-up (GP controller)? Also, weirder things have happened, but are the new plugs good? The engine may initially start since outside temp's are warmer right now, but then run rough until it's warmed up. I've noticed even on hot days, my plugs still light up.

[moondoggie]

Good Day!

White smoke is commonly:

glow plug system
air in the fuel
retarded injection timingHave you only run it idling, or has it been fully warmed up & run at highway speeds / load?

Blessings!

[Sando]

Thanks guys, We have run it to where we think it has started to warm up including a trip of about 4 miles to another shed but didn't seem to make a any difference. We are in the tropics of Queensland Australia so outside temps are certainly not cold. I keep wondering about timing but would it run at all if we ended up a tooth out on the timing gear?
cheers, Sando

[Robyn]

Not an absolute but there are a couple of injector lines that you could have swapped. (At the pump) This will make the thing run horrible as well as dump huge clouds of smoke. Sort of like mixing plug wires but these wont backfire just smoke a lot. :eek:

The two top High pressure fittings are 1 and 8 looking from the drivers seat and going clockwise. -->
Firing order is 1 8 7 6 5 4 3 2 RH cylinders are 2468(Pass side) LH is 1357 (drivers side)

Trace out the lines and be sure they are on the correct ports.

They all will smoke a little after a new pump install but that goes away in a few minutes.

Let us Know :)

Robyn

[twaddle]

Hi Sando,
I think that Robyn may probably mean "Drivers side" as in the LHS of the vehicle as in most cases in the US of A, whereas your steering wheel/drivers side will probably be on the RHS of the vehicle with you being in OZ.

Good luck, I hope it is just a couple of pipes on the wrong way.

Jim

[moondoggie]

Good Day!

What she said. This comes up rarely but regularly. Apparently two of the injector lines are extremely easy to cross.

Blessings[/center

[Robyn]

I do hope this is all it is. Easy to fix and then you should be good to go.

[Sando]

The two top High pressure fittings are 1 and 8 looking from the drivers seat and going clockwise. -->
Firing order is 1 8 7 6 5 4 3 2 RH cylinders are 2468(Pass side) LH is 1357 (drivers side)


Thanks for the replies. We have finally found some time to get back to this, especially since we have to dismantle half the engine just to see where the injection lines go, however we may be onto something.
Robyn, could you double check what you said before please as I have copied above. The firing order on the inlet manifold says 1 8 7 2 6 5 4 3 but what I really need is a sure fire way to figure out the order of the ports on the injection pump. We currently have it all plumbed in the right order except that the top two fittings on the IP looking from the seat and left to right are 8 and 7 where you say it should be 1 and 8. I hope we have found our problem.

Thanks again, Sando

ps, I have got the hang of the drivers and passenger side thing. I could really confuse the issue by saying that my drivers side is on the right side but I won't.:)

[Robyn]

OMG :eek: My mistake.
This is why I keep little pictures hanging around

The numbers on the manifold are perfectly correct
here is a pix of the pump ports with the order of connection

Sorry for the goof, this is one reason to always refer to the specs especially on the tech stuff like torque and of course firing orders.

Print a copy of this little diagram and have it plastic laminated and then stick it in the tool box

Sorry about the RH LH thing too. I rarely see any rigs with RH drive here in Oregon.
The occasional mail wagon will come by that is RH (Subaru mail cars are seen at times)

Robyn

[Mikeandwendy74]

Never rule out the possibility of a failing head gasket, that will give you smoke guaranteed keep an eye on the coolant level.

[rustyk]

I ran into this issue on my Ford /IH 6.9L NA diesel. The issue turned out to be the fuel return lines were sucking air. Replacement solved the problem. Check those things for leakage (and replacement isn't that big of a deal, and probably is needed anyway)

[Sando]

Thanks everyone for their replies. I finally got a chance to get back to the 6.5 and then I haven't been able to get the forums to load for a few days. When we went digging it turns out that the IP had slipped round to fully retarded. I advanced it quite a bit and retightened it and we are away. I haven't quite got it right yet but at least it is on the road. I still think I can advance the timing a little more yet, it is still pretty flat, but will get to it. Also had the fuel filter of and put it back on so that that may have been part of the issue, maybe.
Thanks again, Sando

[Robyn]

Good to hear :)

Robyn

[moondoggie]

Good Day!

Thanks for posting the resolution to your problem. It now becomes part of a really large searchable database of sorts, our forums. :)


Blessings!
(signature in previous post)

[lee5]

I had a similar problem. Took it to dealer to diag. problem said inj. pump replaced.comp No luck. Did a compression check myself found one cyl low comp. Pulled head turned out to be a lifter had came apart replaced fixed problem. Had this happen once snice. I don't know if this is a common problem or not but it happen to me twice. The so called experts did not find it. Good luck