Volvo EC15B mini - engine removal & injection pump overhaul - plus ......

[jackpreacher]

Blue Smoke, No Power, No Patience

1. The injectors are in but the performance is as bad, or a little worse than before.
2. The engine starts fine and idles smoothly but on revving up there is a clatter - a bit like a dodgy valve or big end, but I am guessing.
3. There is hardly any power to move let alone operate. On application of any hydraulic service the engine tends towards stalling.

Any ideas?

For the moment I've started to remove the whole engine again and will strip it down to inspect and rebuild.

[ianoz]

Gees , Lucky you didn't wait till friday the 13th to do this .Who knows what havoc would have happened .

[jackpreacher]

Onwards...

Friday 11th Jan 2013

1. Refitted renovated injectors.
2. Removed IP to install shim - Lo and behold, the original shim was still there, so I hadn't chucked it after all
3. Two of the four bolts securing the IP to the engine sheared off on tightening. The service manual does not state the torque settings for these bolts, or, if it does I can't find them. I didn't do them that tight but maybe the fatigue of refitting/removing the IP has weakened them.

TBC

[jackpreacher]

Time waits for no Volvo, so Doug has to wait until the first week in January before I can try him out with his serviced injectors and proper 'timing' shims in place. I will continue to notate/photograph from then.

There is more to the IP shims than meets the eye though, as Stock & Muz observed. I suspect that the original shim (which I chucked) was probably the correct thickness.

TBC

[jackpreacher]

So I'll start with the thickest shim (which, from memory is thicker than the one I chucked) and work downwards. The thicker the shim the less plunger displacement, the less fuel 'shot'.

[jackpreacher]

Might have something to do more with the correct displacement volume of fuel than timing.........

Bang on.

[jackpreacher]

I think you are right .. Plunger height is displacement

Of course it is!,, stooopid Jack

Thanks chaps - that's possibly why the blue smoke was occurring after the IP repair - far too much fuel, hence injectors fouling, hence less power, hence....er.......hence

[jackpreacher]

Might have something to do more with the correct displacement volume of fuel than timing.........

Yeah, Muz got it - it is the equivalent of advancing or retarding the ignition and NOT the timing of the IP. I assume the volume of fuel 'squirts' will be fixed by the IP port capacity, but when that volume is released to the injector may/may not be critical. Anyway, the procedure to get the angle of the IP cams correctly setup is straightforward but a little daft. I'll copy the relevant part of the manual tomorrow and post it here - you'll see what I mean by daft

[Muz]

Might have something to do more with the correct displacement volume of fuel than timing.........

I think you are right .. Plunger height is displacement

[Stock]

Might have something to do more with the correct displacement volume of fuel than timing.........

[Muz]

1. Got the injectors back today - fully serviced by a professional.
2. After reading the service manual PROPERLY the penny dropped that the 'gasket' for the IP is not a gasket at all - it's a shim to calibrate the timing of the Injection Pump, and these 'shims' come in varying thicknesses from 0.2mm up to 1.0mm, and the timing is set up by getting the correct height of the IP above the timing camshaft. I thought it was just a gasket, and CHUCKED the @#^%+ng thing weeks ago and used silicone gasket sealant instead.


Ordered a set of shims for around £16 plus FAT.

Will set the timing up on Thursday.

Hmm .. I didnt know that .. but it isnt really timing .. thats done by the gears in the timing case, which are notched accordingly, and cannot be 'out' otherwise the engine will not fire.

What you may have found is a way to 'advance' or retard the injection process, which can over fuel the engine a little or otherwise

Ive had One of volvos fitters , a few years ago re seal with silicone and I thought nothing of it, it didnt change the engines performance .. be interested to see what you find Jack

[jackpreacher]

Does it require spill timing??

I think so - the manual doesn't mention the term "spill", but it amounts to the same thing - using the timing marks to see when fuel is delivered to the injector by removing the pipe from the injector and observing the exact crankshaft location when the IP port opens and let's fuel 'spill' out.

I'll add photos of the procedure on Thursday, unless life blunders in the way........

TBC

[Stock]

Does it require spill timing??

[jackpreacher]

Injection Pump timing



1. Got the injectors back today - fully serviced by a professional.
2. After reading the service manual PROPERLY the penny dropped that the 'gasket' for the IP is not a gasket at all - it's a shim to calibrate the timing of the Injection Pump, and these 'shims' come in varying thicknesses from 0.2mm up to 1.0mm, and the timing is set up by getting the correct height of the IP above the timing camshaft. I thought it was just a gasket, and CHUCKED the @#^%+ng thing weeks ago and used silicone gasket sealant instead.


Ordered a set of shims for around £16 plus FAT.

Will set the timing up on Thursday.

[jackpreacher]

Ah but you are getting there though .. I might have a working set of injectors you could try, and that would at least eliminate that problem I'll have a look

That is amazingly generous of you Muz, and a couple of hours ago I would have snatched your hand off - however, by chance a retired injection specialist from Workington rang me back and, to cut a long story short, I just got back from his place after delivering my injectors. He examined them, banged out my nozzles and then showed me what decent nozzles looked like.....what a difference! Cost will be approximately £60.00 per nozzle and guaranteed for 12 months, providing I use decent fuel. He works from a little add-on workshop at his house and retired a few years ago but still likes to tinker - he has all the proper test kit (he showed me round) and appears to know his stuff. I much prefer keeping business local so it feels much better to give him the job rather than send it off to the big boys in Lancaster or London.

When I get the injectors installed and tested I'll report back and name drop this Diesel injection specialist.