Black smoke and misfire on idle

[ne_surf]

I'm wondering if anyone can help me out with a bit of a problem.
I have a gen 2 3.0 that's bellowing black smoke, missing on idle and also takes ages to start.
The other problem which started at the same time is that the glow plug relay takes ages to click when it's cold.
I'm guessing it's either fuel pump or ECU related?
The injectors have all been reconditioned, new head, compression has b en tested.

[tashtego]

Have these symptoms started just after the head replacement?
If so, maybe the job was not done properly? It's not an easy job, contrary to popular belief. Lots of things can go wrong if not done by the book. Most head jobs I have seen done here, the engine never runs the same again, due to poor standards and workmanship.
If not related to the head job, then I would:

1) get glow plug tested ,correct voltage etc
2) check oil is not too thick, when was it last changed ? I'm a fan of 5w synthetic oils for kz te...Castrol Edge, Shell helix etc, every 5000 km.
3) replace air and fuel filter

If all is ok and no change then start investigating pump, ecu etc.

Cheers

[Tony Kingston]

It sounds like a timing problem to me. If the problems have started since the replacement of the head, I would double check the timing belt paying particular attention to the fuel pump timing marks.

Good luck

[ne_surf]

Thanks for the replys.
I haven't had chance to look at it yet, My gen3 is having a 4wd issue that needs sorting.
I'm going to have a good look tonight and I'll update then.
Thanks

[ne_surf]

Update

Timing all seems to be correct, apart from I cant seem to see any timing marks on the pump? Anyone point me in the right direction so I can check that. I have done a 2.4 before and the marks were a mile away! Just cant seem to find any pics on here of the 3.0.

Glow plugs all work and are correct.

Air filter was new 500 miles ago, and looks clean.

Replaced the fuel filter and added forte cleaner (trade only stuff)

The thing I have noticed is that the SPV had been played with, rounded lock nut. Is there a way to set it back to original? I have checked the resistance and it is 2.5ohms.

I have read the fault codes and got; 24 Air Temp, 32 Air Flow, 35 Turbo pressure just going off what I have read on here.

[The Boo Crew]

Check all the vac pipes are connected there are many!

[Tony Kingston]

Here's some pics

[ne_surf]

Check all the vac pipes are connected there are many!

I have replaced all the vacuum pipes, they were all perished. Iv had a few of these and all the rubber is about rotten now

[ne_surf]

Here's some pics

Thanks for that! Brill

[ne_surf]

Does anyone have any info on how to test the sensors (correction resistors, speed sensor, SCV, timing control sensor) on the pump?
I don't want to remove the pump without testing everything

[ne_surf]

Update

I have set to testing everything I can;

EGR blanked
Tried the trade quality injector cleaner
Replaced all the pipework leading to the pump, even fitted a clear section to check for air. No air in the system, and no run back.
The ECU has been reset again only fault code now is 35 turbo pressure sensor, found some cracked vacuum pipes so replaced every single one. ECU reset so I'll see if that's worked.
Checked, rechecked and checked the timing again. All spot on.
Spill control valve checked
Glow plugs checked, resistance is a little high but they are working. Although the glow plug ligh seems to only work when the motor is warm. And when starting from cold there is no click until about 30 seconds...

I need to check the pump resistance, has anyone got any info??
If I can check the pump and all is good, next port of call is ECU sent away and checked.
Then finally if all else fails new pump.

Anyone got any input? It would be greatly appreciated. Everything I have done has had no affect on the black smoke and Miss on tick over.

[bryanisaoldgit]

R U sure that the injector pipes have been
put back on correct
ie number 1 inject to num 1 on pump rear end
they can be put on half a cycle out
and will start and run as u decribe sometimes
or one inject could be naf and overfueling
worth a check
or even yer cam could be half a cycle out

[ne_surf]

R U sure that the injector pipes have been
put back on correct
ie number 1 inject to num 1 on pump rear end
they can be put on half a cycle out
and will start and run as u decribe sometimes
or one inject could be naf and overfueling
worth a check
or even yer cam could be half a cycle out

Thanks for the advice, I have already checked both of those things.

I have finally gotten to th bottom of the issue...
Sniff test done - passed
Compression test done last week - with my £25 tester off eBay PASS
Compression test done again with a better more expensive SNAP ON tester - FAIL!

Head gasket FAILED!!

I noticed that the truck had also developed a pretty bad oil leak, which I thought was down to the usual rocker cover gasket. Upon removing the heat shield from the exhaust I seen that oil was leaking from the whole length of the block! Wiped it off, ran the truck, oil all the way along within seconds.
Further investigation; head bolts were slack, 2 within the rocker cover area were not even finger tight!

New gasket set, all bolts torqued to the correct settings. Runs like a dream!

Thank you everyone for your advice, it helped me rule things out

[Diezel Weazel]

10 outta 10 for perseverance Buddy enjoy n Good Luck



16+ Years of Surfs, now KZN 130, 9 years on Spotless it ain't but Faultless to a "T" is my Yota !!

[Tony Kingston]

Well spotted, thanks for closing it down.

Glad you got it sorted.