Is this ok?

[andyverran]

Sounds like a sensisible course of action to me...

[RebelV8]

A good day today, took the rocker cover off and checked all was ok with the valves and lifters, all seems in order with equal clearance tolerance's on them all. Replaced the glow plugs with the new ones and fired it up, made temporary repair to the section of pipe that joins the inlet manifold to the EFI tube as it was split quite badly and seemed to be allowing air into the system. Adjusted the throttle cable to be give a more responsive throttle with less play at the pedal. Slight adjustment to the potentiometer positioning and all seems a lot better with much improved starting and idle, performance is up as well (as much as it can be on a 2.4, lol). Also made a small adjustment to the steering box to make the steering a bit more responsive and remove the small amount of play that it seemed to have. My Surf is now idling smoother and driving better, the turbo light comes on at about 1800rpm now and not 3500!, the load sensor also seems to be working properly now as well.
My new number plates also arrived this morning, ready to fit. If this keeps up I'll have to tax it and start using it daily, lol

[andyverran]

Great result there then! Nice one.

[ToyotaRon]

Yep, well done that man!

[RebelV8]

Not out of the woods yet though, taxed it today and did a couple of local runs in it before using it for work tomorrow.
Runs and drives, but seems to be idling slowly (too low revs), on idle whether up to temperature or not, it sits at about 600rpm, is this right or should it be sitting at about 750rpm? if it's too low, is there a way to increase the rev's?
Also checked the fluid in the gearbox and it was low (I lost some when putting the engine back in). I topped it up with as much ATF as I have and it's now sitting at the bottom of the cold mark on the dipstick. Does anyone know how much ATF I'll need to move it from the bottom of the cold mark to where it should be on the dipstick when checking it with the fluid hot?
Other than that, it runs, drives and stops, the turbo kicks in when it should and the kick down works, most importantly though, it doesn't or hasn't overheated, just goes to about 12 oclock on the temperature gauge and stays there.

[RebelV8]

At a bit of a loss now

Still having problems with the way the Surf is running, I've adjusted the timing on the injection pump by turning the pump a little, it started better yesterday after doing this. Went for a drive and power was up but the idle still seemed low at approx 600 rpm. Just been out to start it again and it was difficult to start with a cloud of grey smoke and smell of diesel, I'll try turning the injection pump slightly closer to where it was again, but other than that I'm lost.
I've checked that everything that should be plugged in, is plugged in. I've removed the EGR valve and only have the plugs left from the VSV connections for the EGR valve, do these need to be connected to something?
Anybody have any other ideas?

[RebelV8]

Still not happy

I've made some more adjustments to the position of the timing marks on the injection pump and thought I'd sorted it. Left it overnight and tried to start it this evening.
Bad news is that it took three attempts to start, good news is it did start. The weird thing is it sounds ok when on tick over and is idling at about 600rpm which I think is a bit low to be honest.
I'm not altogether sure that I'm helping make things better or worse though, the symptoms are as follows,

Hard to start (at least three attempts every time)
Engine shaking when started and when on tick over
It sounds just not quite right when idling

Wish I was closer to some of you guy's, beginning to think I'm missing something small and silly.................

[RebelV8]

Ok then, It'll start with difficulty, it's idling at about 600RPM and the engine shakes on tick over.

I'm thinking, something to do with the position of the timing pump, compression or injectors.

So, going to get a compression tester
busy moving the injector pump to different positions
Should I buy some replacement injectors?

Is there something I could have missed or connected the wrong way round?

I'm tempted to take the timing cover off again just to check the timing marks are all still in line. Could I have the timing 180 degrees out?

Is it possible I've connected a vacuum pipe the wrong way round?

Any ideas?

[andyverran]

Ok then, It'll start with difficulty, it's idling at about 600RPM and the engine shakes on tick over.

I'm thinking, something to do with the position of the timing pump, compression or injectors.

So, going to get a compression tester
busy moving the injector pump to different positions
Should I buy some replacement injectors?

Is there something I could have missed or connected the wrong way round?

I'm tempted to take the timing cover off again just to check the timing marks are all still in line. Could I have the timing 180 degrees out?

Is it possible I've connected a vacuum pipe the wrong way round?

Any ideas?

Evening Rebel.

Worth double checking the timing ... If it won't run right with the pump timing in the correct place something must be wrong...don't think I can shed any light mind, but always good to check the usual suspects it may help to eliminate possibilities.

Have you checked out NiftyNevs posts on the EGR and its removal/operation?

Good luck as ever dude.

[RebelV8]

Thanks Andy

I haven't checked Nifty Nevs post yet, will do shortly though. I just can't help thinking it's something to do with the timing.

Thanks again

[andyverran]

Thanks Andy

I haven't checked Nifty Nevs post yet, will do shortly though. I just can't help thinking it's something to do with the timing.

Thanks again

A good chance your right I'd imagine...though be a little warry of believing a thing and missing other options, can lead you right up the garden path.

let us know what you find bud, all adds to the learning.

[RebelV8]

Will do

[RebelV8]

Dismantled the front of the engine again today, found something that might provide the answer (if I'm seeing it right).
Looking at all the timing marks and positions of the pulleys, when I look at the timing marks on the crankshaft pulley they appear to be approximately 1 tooth out from the metal prong that sticks out (timing prong?). The camshaft pulley is lined up at 6 o clock and the injector pump is lined up at 12 o clock but the crankshaft pulley seems to be one tooth away from lining up, could this be my problem?

I've posted a pic , timing marks on the pulley in white and the prong that sticks out is in yellow, I know it looks close in the pic, but when you're stood in front of it looking down at it, it appears to be out by 1 tooth.

I'm thinking that in theory, I need to adjust the crankshaft by one tooth to align everything perfectly?

[BUSHWHACKER]

I'm thinking that in theory, I need to adjust the crankshaft by one tooth to align everything perfectly?

Yup.

It's been a number of years since I've tinkered with a 2.4, but the 'trick' was to set the crank timing mark one tooth before TDC so that when the tensioner was released, the belt 'pulled' the crank mark into position, IIRC.

[RebelV8]

Thanks Vince

Job for tomorrow then, get it all lined up