2.25 diesel problem

I've got a problem with the 2.25 diesel in my 110.

6 months ago it developed a rattle from the top end of the engine and started smoking more. I changed injectors and had the fuel pump overhauled but the rattle persisted, so I took the head off. One of the injector inserts fell out when I took the head off, so great - fault found! I had the head overhauled (new injector inserts, valves lapped in, head ground etc etc) and refitted it to the engine.

Since then I've been struggling to get it running. I finally got it to go today, having played around with the pump timing abit. The problem is that I now don't know whats still wrong with it

It is still smoking quite a bit (grey/black), it wont run at tickover (stalls first) and there is quite a distinct noise from the engine when its running (bit like a double bang). It also hunts a bit at governed RPM.

I have advanced and retarded the pump with no noticable change to it.

Any one got any suggestions?

Cheers

Andrew

If it's only just been put back together and you haven't been for a good run in it since the work, it's almost definitely a fuel problem, ie. starvation or contamination. I'd suggest checking all of the fuel lines and hose connections between the fuel filter housing and the injectors (including lift pump and injection pump) to ensure that they are tight and attached as they should be.

Next thing to try is checking for air in the system. This can be done by undoing the bleed nut on the injection pump (see nut just to the right below no 10 http://www.skuf.co.uk/temp/pump.jpg) slightly and then manually pumping fuel into the pump via the lever on the lift pump until fuel appears to be coming out from around the nut. If you see any bubbles > there is your problem!

I've just rebuilt my 2.5 N/A diesel engine and it was a total bugger to get going the first time. I actually ended up flattening my battery.

Where abouts are you?
-pos

I had already put in a clear plastic pipe between the filter and the injector pump to see if there was air getting into the system but it shows a nice clean supply of diesel.
Pump was bled through and came through clean and air free as well.

I'm suspect my timing is out, but really don't know if its too advanced or retarded.

Cheers

Andrew

CharlesY has written up many guides to fuel injection pump timing, here's a link:

http://www.landyzone.co.uk/lz/f6/smoking-series-3-diesel-44486-2.html?highlight=injector+pump+timing

-Pos