Diesel engine health

[Xulfiqar]

im sorry to have misunderstood your post, you marked the gauge with the units in PSI, I mistook it for your engine compression reading - but if your compression was spot on - above 400 psi on each cylinder with less than 80 psi variation between the cylinders the engine is "solid"

you seem to be quite handy in finding right stuff - I believe you can easily make the valve press tool to change the valve seals with head in place.

you yourself also answered your question of "setting it to toyota specification" - the engine will perform the best and the longest on that setting.

[ali_ak]

Thank you. I also feel more confident now.
You have mentioned about seal replacement tool earlier, kindly explain a bit more or give some relevant link.
Also elaborate what is the better method of compression test. with limited 5 maximum revolutions, or reving the engine until we get max pressure reading.

Regarding the Compression test confusion (if any).

Scale in Picture is mega pascal, I have indicated both Kilo pascals and PSI. This was my 1st compression test at Toyota Centre, then i tested at another place next day as well.

The three marks on the scale in picture are equal to 2850 2950 3050 K Pascals or 413, 427 and 440 PSI. Cylinder 1 either match value of cyl2 or cyl4 (actual pin of gauge in picture).

Small red and blue lines, and actual guage positon indicated 3 readings, 4th one was also equal to 1 of these 3. The long Yellow lines Indicate toyota specified Maximum and Minimum Pressure range.

Readings matched with my 2nd day results on a 1000 psi diesel compression kit, but this time i followed instruction of some forum for noting down 1st revolution pressure readings, and noting down reading of 5 revolutions only.

The readings in picture (toyota) were obtained by giving upto 10, or may be 15 revolutions until scale increased no more.
But when I limited the revolutions to 5 maximum in my 2nd attempt, Pressure Ranges were 380 to 420 PSI, While pressure of 1st revolution were 160,180,200/210 (not indicated in cylinder order).

Regards

[Xulfiqar]

the compression is tested till the gauge stops moving, its usually done by about 8 pushes.

[ali_ak]

Well in that case all readings are above 400 psi.

Today I visited to Brandeth Rd Lahore in hope to buy Injection Pump Timing Gauge. Didn't found any

Returned with a vernier calliper, feeler gauge, ratchet spanner and address of INH workshop which is very near to my house, and is twinned with PORCHE workshop. I expect they have diesel calibration laboratory and timing gauges, but they are supposed to cost me high.

The guy who recommended it said INH is one of the best Workshop in whole pakistan etc. He also had a whole portfolio of some company with expensive gauge of all kinds. He seem to be a knowledgeable man. When i asked him where he gets his own car repaired, his reply was the most wise that I have tested myself. He said, "I have XLI 07 and I have never taken it to a mechanic."

I also have a Mehran03 and I have never let a mechanic touch its carb, this never letting mechanic do anything eventually pays of as I have many friends who have much newer Suzuki cars, but their carbs messed up by suzuki itself for a worst performance.
Even in pakwheels, all those people who have issues with their carbs were at some time trolled by some idiot to service their carbs.

Very disappointing state of affairs.

Any one has any idea where to get the Toyota Diesel INjection Pump timing gauge???

[Xulfiqar]

you make the tool yourself
items required

1 x dial gauge that can measure 0.01mm increments
1 x round bar stock that can be machined = no springy quality - abt 15 cm long
1 x pin that can will be used to insert in to bar stock for the gauge plunger to read.

find an injection pump high pressure head center plug bolt - its 8x1.25 thread - about 25mm long I think - mill the bar stock to have this thread at one end, now drill a hole in said bar stock through the centre and make sure your pin can also slide neatly with some oil applied - pin should not slop side to side. - now mill bar stock on other end to make a receptacle for the dial gauge tail - drill a hole 90 degrees to the milling and use a thumb screw to lock the dial gauge into the tool.

you have your tool.

now you can play with it.

there is a gent here on PW who took his benz to INH and he did not display a pretty picture honestly.

[ali_ak]

Thats bad. Ok i guess I will have to do it myself.

Hey, I have found a video on youtube about VE pump calibration. I am sharing it with time breakout of each part.

Please shed some light, the video seem very relevant to what you have been saying things earlier and I have quoted below.

Regards

Diesel Pump Calibration VE - YouTube

1:14 Full Load adjustmen
I guess this adjusts fuel cc at certain rpm
1:50 Pump pressure adjustment
hammering to increas pressure
3:33 Max speed adjustment
4:45 Idling adjustment
Screw adjust for max/min throttle
5:35 Starting Fuel Delivery
Not sure what is this adjustment, something to do with starting probably
7:11 Timing Advance Measuring Device
A Special Appratus is attached
Air is bleeded
Measured Timing Stroke Advance at different RPMs
14:32 Load Timer Adjustment
Not sure whats this
Seems like same adjustment is done for which Dial Guage is used,, loosening the bolts and adjusting the pump, not sure though.
15:18 Overview of adjustment points for the specific case

ok - lets see here

assuming you have the original injection pump and everything is top notch perfect, (rotor head set correct etc.) correct set on the bench and it can push out fuel correctly (no air in hard lines)

the injection quantity at 1400 rpm is about 14.05 ~ 14.36 cc - measured at 200 strokes
measuring at 1200 rpm is 13.96 ~ 14.28cc @ 200 strokes measurement

^^

assuming you have a boost aneroid pump and is pressed with 9 psi air and accelerator pulled to full (this is full load volume) - the volume if you measure it at 2300 pump rpm the volume should drop to 4.5cc as the governor kicks in

make sure the internal pump pressure is 40-50 @ 500 pump rpm and approximately 100 psi @ 2100 pump rpm.

the advance system is measured with timer device - does your injection pump test shop have this instrument? The internal pressure is measured with an adapter on the denso timer measuring device too - you adjust internal pressure with the outflow regulator that is screwed into the pump - adjustment is made with hammer and mandrel - dont overdo it because you would need to replace the item if overdone.

If you can find a shop that understands pump advance, internal pressure, metering sleeve action etc. you can give them a try

[f_khan]

i hav installed new denso injector part no 23670-30050 made in japan, instead of original 23670-OL110, after installation new injectors eprom didnt accept/save it compensation code, and errors occur invalid input. when i installing original injectors 23670-0L110, its eprom accept its compensation code. DTC are cleared, engine is running condition and rattling sound observed in engine. is it save to run engine without compensation code. mostly road side gurus says we installed injectors only and cleared its DTC and no fault occur since long. plz help me in this regards.

[Xulfiqar]

the load timer adjustment is the reaction speed at which the rpm governor of the pump moves forwards - its a spinning centrifugal device that is also used as a max rpm adjuster (it will pull the pump fuelling back to prevent the engine from destroying itself)

When this pump is ready to be installed the dial gauge and adapter are used to measure the pump position relative to the engine timing - this places it exactly where it needs to be for it to work like it should.

This video is pretty nice - all this equipment is supposed to be used as standard but most deezal pump shpeshalist retail shops dont have them. This video was missing the boost aneroid (video has NA engine pump) - those pumps have additional settings to work on.

[Xulfiqar]

i hav installed new denso injector part no 23670-30050 made in japan, instead of original 23670-OL110, after installation new injectors eprom didnt accept/save it compensation code, and errors occur invalid input. when i installing original injectors 23670-0L110, its eprom accept its compensation code. DTC are cleared, engine is running condition and rattling sound observed in engine. is it save to run engine without compensation code. mostly road side gurus says we installed injectors only and cleared its DTC and no fault occur since long. plz help me in this regards.

no calibration data in the diesel control unit will cause the engine to rattle and also wear out quicker, the road side gurus who just clear DTC and slap on injectors are the original reason for the high sales of used scrap injectors and whole engine assemblies - (toyota also play their part in making a POS engine)

[f_khan]

^^
so how to resolve my issue, is it wrongly purchased injectors or fake / duplicate injectors, shopkeepers is my friend n help me out a lots, he assure me that injectors are 100% original and not fake. is it any chance that unique code have secretly code regarding origin, and pkdm hilux 2kd engine ECM only accept thai brand i-e 23670-0L110 and its compensation code.

[ali_ak]

1 x round bar stock that can be machined = no springy quality - abt 15 cm long

What diameter? i guess bigger then 8mm (bolt size).

1 x pin that can will be used to insert in to bar stock for the gauge plunger to read.

What kind of pin?
Can a metal rod of 1mm dia or something like that will work???
What Length??

find an injection pump high pressure head center plug bolt - its 8x1.25 thread

I think this: http://cdn.instructables.com/F1Q/XB18/H1JUGLMQ/F1QXB18H1JUGLMQ.MEDIUM.jpg
and this: http://www.convertiblewindscreen.co.uk/images/azzinjectorpumprotortimingplugthumb.jpg

mill the bar stock to have this thread at one end,

You mean,,
create threads inside the bar stock so that Head Bolt can be fastened?? (threads of bolt goes inside the bar stock)
OR
Some how fix the Head of Head bolt in Bar Stock, while Thread side faces outside.

now drill a hole in said bar stock through the centre and make sure your pin can also slide neatly with some oil applied

by CENTRE you mean along the length of barstock, right??
Should it pass through Head Bolt as well??
I am confused about this step.

pin should not slop side to side.

You mean pin should have no play other then linear motion, right??

now mill bar stock on other end to make a receptacle for the dial gauge tail - drill a hole 90 degrees to the milling and use a thumb screw to lock the dial gauge into the tool.

I think this is the required Dial Gauge Micrometer: http://cdn2.bigcommerce.com/server1500/6c8df/products/222/images/200/1400_Dial_Indicator_Depth_Micrometer__40646.1405391852.1020.660.jpg?c=2

I don't get what meant by 90 degree, and fixing, please elaborate more.

Whats the purpose of Headbolt here??

I guess, we remove pump HeadBolt, attach our gauge using headbolt, which has a linear pin that touces some plunger inside the pump, and transfer the linear motion to Micrometer.

Probably the purpose of barstock is to remove play in the linear motion pin.

Please elaborate.

Thank you, and best regards.

[Xulfiqar]

The bar stock theeading should be outside. Your barstock tool gets threaded into the pump. the bolt you remove from the high pressure iron head of the pump does not need work. It goes back into the pump when this job is done.

the bore to receive the gauge should haveva screw threaded from the side so you can lock the gauge in the bar. the pin should be a 2mm rod that goes through the bar and into the pump head and contacts the plunger.

[Xulfiqar]

^^
so how to resolve my issue, is it wrongly purchased injectors or fake / duplicate injectors, shopkeepers is my friend n help me out a lots, he assure me that injectors are 100% original and not fake. is it any chance that unique code have secretly code regarding origin, and pkdm hilux 2kd engine ECM only accept thai brand i-e 23670-0L110 and its compensation code.

You need correct injectors your dcu wont accept wrong injectors

[ali_ak]

Today, i visited INH workshop, and it seems I was trolled by the guy who recommended it to me

Main contact was not there, so i asked the mechanic what they do with Diesel car and he was, "ji khol k lab bhaj dete hain" :X

Which Lab?
Asif Shah at kot lakpat area, that guy seems to be famous.

Final Q, how do you adjust the pump when fitting back.
"Awaz jidher set ho"

:@ :@ :@

By looks of it INH was average workshop, Toyota Dealerships are much better and neat.
But many old and new Merc and other luxury cars were getting repaired there, may be they have few special tools for them.

[syncview]

Asif Shah is a rip off never go there
In fact every diesel lab in Lahore is a rip off

[ali_ak]

Asif Shah is a rip off never go there
In fact every diesel lab in Lahore is a rip off

Thanks for sharing your opinion. What do u recommend?

I have also been told a place, name is something like Mahr Asif or Mehr Asif (may be arif), some where in Daroghawala. Its some big Diesel Lab in that locality.

[syncview]

I haven't worked a lot on diesels, I have had good luck with a Nissan Patrol 4.2 diesel and 1KZ prado - sent their pumps and nozzles to diesel power systems in KHI, as recommended by Xulfiqar

the results were amazing, although a little expensive but still, better to pay a little more than to pay to a rip off and waste all of it.

here is a contact# 0333-699-3933 - Muzammil Hussain - it's been a long time since I called this number but, you can try or get their contact info from their website - keep your car's frame# handy before you call.

[ali_ak]

Hey thanks.

I was thinking on same lines. I will contact him.

Regards.

[ali_ak]

I have tried the number, nobody is picking up
@xulfiqar sb
is DPS and Cummins Pakistan same or two separate entities?
Is their location "2 Banglore Town, Shahra e Faisal"

I can send some one their to contact them.

Regards

[Xulfiqar]

yes they are the same entity. and that is there address.