2005 Warrior K74 rough idle and black smoke after engine replacement

#1 by Daviemtc , Mon Nov 30, 2020 7:17 pm



Following a fekin disaster with the previous rebuild , i bit the bullet and replaced the engine with a brand new Milners job , Block and head.
Fitted the engine fine, all ancillaries fine, just one minor issue with dirty starter connection .
Engine starts well, runs a bit lumpy and when i put the foot down i cannae see th road behind for black and nasty smoke.

Before refitting I stripped the injectors down and gave them a good clean, haven't got testing kit so couldn't do that. fitted new leak off washers these only got 2 holes originals had 3 would this make a difference ?
Before the previous engine committed suicide externals seemed to be working fine, Turbo / Fuel pump both good.
All timing marks line up perfectly.
Set valve clearances to 0.15mm cold then checked them at 0.25mm hot these were spot on.
Checked injection pump timing today this is also spot on.
Running a K&N Apollo induction kit with recently cleaned and oiled filter so no breathing problems.
No warning lights , so haven't run a diagnostic yet, but to be fair only driven 4 miles.
Is this probably feked injectors? Any way of testing without specialist kit.
This is doing my fekin nut in . Only getting about 9 hours daylight too so working under a headtorch mostly after dark o clock.
Any Ideas Anyone.

Cheers Davie


If it's not broken yet, you're not trying hard enough.


 
Daviemtc
Posts: 296
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RE: 2005 Warrior K74 rough idle and black smoke after engine replacement

#2 by 123hotchef , Mon Nov 30, 2020 7:54 pm

yeh id say u fooked the injectors or by taking them apart, milners ones are £50 each. I took 1 apart on my shogun a few months back had si ilar issues purchased a set of 4 from ilners just replace the one i messed with all was good after that


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RE: 2005 Warrior K74 rough idle and black smoke after engine replacement

#3 by 123hotchef , Mon Nov 30, 2020 7:55 pm

or u have a vac pipe mixed up


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RE: 2005 Warrior K74 rough idle and black smoke after engine replacement

#4 by Daviemtc , Mon Nov 30, 2020 8:28 pm

i did the same stripdown a couple of years ago and all worked fine afterwards, these were the same injectors mind you. I cleaned them all so i no lookin forward to the £200 +
Vac pipes all good.


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RE: 2005 Warrior K74 rough idle and black smoke after engine replacement

#5 by Heathen , Mon Nov 30, 2020 10:09 pm

I've stripped/cleaned all the injectors on mine before without any problems. I'd be suspecting the leak off washers - if you've got pressure building in that part of the fuel system, this would result in forcing more fuel into the cylinders -> overfuelling -> black smoke. Plus they're a lot cheaper to test than new injectors.


'02 K74 single cab.


 
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RE: 2005 Warrior K74 rough idle and black smoke after engine replacement

#6 by Daviemtc , Mon Nov 30, 2020 10:39 pm

Aye I was hoping somebody would say that , I'll bang the old ones back on tomorrow and see if it makes a difference.


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RE: 2005 Warrior K74 rough idle and black smoke after engine replacement

#7 by Daviemtc , Wed Dec 02, 2020 1:14 pm

Swapped washers no change. I did notice when the engine was running a slight wobble in the injector timing sprocket when the engine was running. Stopped the engine and found I could push the timing sprocket/shaft back about a mm or so , looked at another pump I've got kicking about and it does the same, is this normal or an obvious sign of wear . Was watching an interesting vid on u tube link below.
https://www.youtube.com/watch?v=G1EDafTg_8o
I know its a different pump but it would suggest this could be the problem.
Anyone had similar issues or am I barking up the wrong tree.


If it's not broken yet, you're not trying hard enough.


 
Daviemtc
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RE: 2005 Warrior K74 rough idle and black smoke after engine replacement

#8 by Daviemtc , Wed Dec 02, 2020 1:16 pm

Aye I forgot to mention in my OP there's copious grey smoke on tick-over too.


If it's not broken yet, you're not trying hard enough.


 
Daviemtc
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RE: 2005 Warrior K74 rough idle and black smoke after engine replacement

#9 by Daviemtc , Wed Dec 02, 2020 1:21 pm

Checked for fault codes got a 52 up too , have checked all piping and it fine, can I test the actual solenoid? and how. Milner out of solenoids. anyone know of a reputable supplier that charges less than £100 for genuine ones.


If it's not broken yet, you're not trying hard enough.


 
Daviemtc
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RE: 2005 Warrior K74 rough idle and black smoke after engine replacement

#10 by Daviemtc , Wed Dec 02, 2020 5:24 pm

Removed VGT solenoid etc. Both solenoids click when 12v applied, tried sucking the vac hose and holding me tongue over the end, no suction. I can blow down the hose with no resistance I can hear the air escaping both times this doesn't seem right. I really need to get a vac gauge, lol/ replaced solenoid array with another which I think is good click when 12v applied and suction seems good. Tried diagnostic again with dash light now it just continually flashes WTF.
pitch black outside now so knocking it on the head.


If it's not broken yet, you're not trying hard enough.


 
Daviemtc
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Date registered 07.27.2016


RE: 2005 Warrior K74 rough idle and black smoke after engine replacement

#11 by Daviemtc , Wed Dec 02, 2020 5:29 pm

I know the ABS warning light flashes continuously if no fault is present, should the EML do the same I thought it was just a no light thing?


If it's not broken yet, you're not trying hard enough.


 
Daviemtc
Posts: 296
Date registered 07.27.2016


RE: 2005 Warrior K74 rough idle and black smoke after engine replacement

#12 by Heathen , Wed Dec 02, 2020 10:50 pm

Wenn Sie hier auf Links zu eBay klicken und einen Kauf tätigen, kann dies dazu führen, dass diese Website eine Provision erhält.

@Daviemtc - Shame the washers didn't work - it was a long shot, but worth a try. Great video there - he reminds me of Fred Dibnah! Mechanics of that pump are the same as on the L200, just it's got a load of extra sensors etc..., Been meaning to do this for sooo long on a couple of pumps, but never seem to have the time or clean/big enough space! https://quietglow.com/dieselvanagon/Bosch_Pump/-Rebuild is also a great resource, but in pictures.

Pretty sure that play is not right at all - I'll check my spare pump tomorrow for that. The front bushing is available if that's the problem - mate changed one recently and I'll get the info of where he sourced it tomorrow as he's coming over to help with a few jobs on the missus' car. pajeroshop-ltd on ebay can provide you with a rebuild kit to replace all the washers/seals etc (mate just reused all the old ones though and it works fine), but not sure if they do the shaft bushing Werbung: https://www.ebay.co.uk/itm/ZEXEL-Total-O...BwAAMXQcVNQ7ti2.

That's a pretty meaty job though - pos easier to just get a 2nd hand pump if you don't have the balls (maybe that's why I have 3 non working spares)... Classic for when the shaft seal/bushing starts to leak is white smoke and no power at low revs due to underfuelling. Sounds like you may have more than one issue going on?


'02 K74 single cab.

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Heathen
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RE: 2005 Warrior K74 rough idle and black smoke after engine replacement

#13 by Daviemtc , Wed Dec 02, 2020 11:25 pm

Cheers Rob. Aye I have another 2 pumps here and they both have that same play in the shaft, i think both have done about 90k, the one on the truck the now has about 160k under its belt.
I'm checking the glow plugs tomorrow .
This is really doing my nut in as everything was working fine before i pulled the old engine out.
Cheers for the pajeroshop link I was looking at the overhaul kit a few weeks ago when I was thinking of fitting new injector nozzles. they give full instructions with the kit too and Plenty of support, Think I'll call George tomorrow and ask about the movement in the shaft. If I do end up rebuilding at least I have a couple of spares for practice and or parts , probably should get new nozzles while I'm at it.
I have a really understanding/enthusiastic missus so any clean work gets done on the dining table. She's even let me put bolt holes in it for the vice.

The last similar thing I did was the P/S box on my 90 a few years ago an Adwest box , Spoke to I think Rob was his name too and he pretty much talked me all the way through the job with the blueprints of the box in front of him, he even sent me some seals that were missing from the kit I got off Paddocks, FOC,

I can strip things down and rebuild them but diagnostics is a bit of a weak spot with me more like expensive trial and error, and I'm running out of kids to sell too LOL.


If it's not broken yet, you're not trying hard enough.


 
Daviemtc
Posts: 296
Date registered 07.27.2016


RE: 2005 Warrior K74 rough idle and black smoke after engine replacement

#14 by Heathen , Thu Dec 03, 2020 9:23 am

Quote: Daviemtc wrote in post #13
I have a really understanding/enthusiastic missus so any clean work gets done on the dining table. She's even let me put bolt holes in it for the vice.
Nice - I'm still working on that! Just had a look at my pump - got no play in that direction at all - maybe you've got a similar problem as in that video? One of mine has a bit of side to side play, which I'm sure is the front bushing, that then makes the front seal give up and then the lift pump draws air into the fuel.


'02 K74 single cab.


 
Heathen
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Date registered 05.20.2016


RE: 2005 Warrior K74 rough idle and black smoke after engine replacement

#15 by Daviemtc , Fri Dec 04, 2020 2:12 pm

Pump away to engineers for testing yesterday. (this is going to hurt).
One of my boys thinks i should've scrapped it when the first engine gave up,(retrospect eh?) my youngest says I'm so far down the rabbit hole now my only option is to keep digging and hope I come out the other side of the hill,( he's a fuking star..) my missus just laughs at me.


If it's not broken yet, you're not trying hard enough.


 
Daviemtc
Posts: 296
Date registered 07.27.2016


RE: 2005 Warrior K74 rough idle and black smoke after engine replacement

#16 by 123hotchef , Fri Dec 04, 2020 7:58 pm

how much play u talking about?


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RE: 2005 Warrior K74 rough idle and black smoke after engine replacement

#17 by Daviemtc , Fri Dec 04, 2020 8:44 pm

Going to try and measure it but it feels like about half a mm.


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Daviemtc
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Date registered 07.27.2016


RE: 2005 Warrior K74 rough idle and black smoke after engine replacement

#18 by 123hotchef , Fri Dec 04, 2020 8:48 pm

thats normal then


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RE: 2005 Warrior K74 rough idle and black smoke after engine replacement

#19 by Daviemtc , Fri Dec 04, 2020 10:25 pm

@123hotchef Cheers Lee. I wasn't sure how much if any end float was acceptable with the pump seeing as tolerances with the timing are so small , I'm still a bit concerned about the apparent wobble though. Would this suggest worn bush? Could that affect the timing so badly that it would cause the smoke then?


If it's not broken yet, you're not trying hard enough.


 
Daviemtc
Posts: 296
Date registered 07.27.2016

Last edited 12.04.2020 | Top

RE: 2005 Warrior K74 rough idle and black smoke after engine replacement

#20 by Heathen , Mon Dec 07, 2020 5:10 pm

After a closer look at my spare it does have the same play - with force, the shaft pushes in about 1/2mm, but springs out again.


'02 K74 single cab.


 
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RE: 2005 Warrior K74 rough idle and black smoke after engine replacement

#21 by Daviemtc , Thu Dec 17, 2020 5:13 pm

Well I think I sorted this out. After much faffing about , and probably unnecessary expense on injectors and glow plugs etc. Keyway in timing gear, crank sensor rotor and crank pulley were all a bit worn, replaced them all, swapped crank sensor .checked pump timing which was spot on and now seems to be running sweet as. Not wanting a proper test drive after dark so will wait till morning now.


If it's not broken yet, you're not trying hard enough.


 
Daviemtc
Posts: 296
Date registered 07.27.2016


RE: 2005 Warrior K74 rough idle and black smoke after engine replacement

#22 by Daviemtc , Thu Dec 17, 2020 5:18 pm

Oh aye cheers @Heathen Rob and @123hotchef Lee ,for your input.


If it's not broken yet, you're not trying hard enough.


 
Daviemtc
Posts: 296
Date registered 07.27.2016


RE: 2005 Warrior K74 rough idle and black smoke after engine replacement

#23 by 123hotchef , Thu Dec 17, 2020 9:31 pm

oh man glad it is fixed though!


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RE: 2005 Warrior K74 rough idle and black smoke after engine replacement

#24 by Nik Rite , Fri Dec 18, 2020 11:07 am

good effort that


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RE: 2005 Warrior K74 rough idle and black smoke after engine replacement

#25 by Daviemtc , Fri Dec 18, 2020 3:31 pm

Just home from 60mile trip to town and back, pulling like a train, or in this rain a tug boat. no leaks , squeaks, smoke, rattles or bumps and no amber lights, I'm a happy little bunny.


If it's not broken yet, you're not trying hard enough.


 
Daviemtc
Posts: 296
Date registered 07.27.2016


   

Reversing in darkness
Headlights flicker as brake is pressed

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