Apprentice needs help

**Duffman** · 27th August 2011, 12:49 PM

I had my 95 300tdi disco at Tafe last week pulled the injectors out put on the test bench and found they weren’t flash so we pulled them apart cleaned them up put them back on the test bench and they weren’t perfect but a big improvement put them back in with new copper washers.
Then adjusted the rockers and put new glow plugs in. did a compression test and all 4 cylinders’ had 380 psi. so thinking all is good went to drive home and now it will not go faster then 90kph before I did the work would get 110pkh on the highway no prob.
What’s most likely to be the issue did I stuff the injectors or could over adjusted rockers be the course or somthing else I need help to work this thing out.

**blitz** · 27th August 2011, 01:08 PM

hmmm will have a crack at this but quite possibly will be corrected.

Depending on what you did when you adjusted the rockers, if you made the gap excessive you now have less time that the rocker pushes down on the valve therefore reducing the duration it is open?

if this is the case you have throttled it so it cant breath properly, if you reduce the gap you increase the valve gap distance and the time it is open for there by letting more air to flow in and out.

That is just a wild stab in the dark.

I cant seel how cleaning the injectors could have possibly made it worse

**Blknight.aus** · 27th August 2011, 02:50 PM

what was the rocker clearance set to?

check for any disturbed hoses that are letting the fuel pump draw air or any fouling of the throttle mechanism...

occasionally the feed line for the boost compensator will be knocked loose while faffing around in the engine bay and this results in the boost compensator seeing no boost and therefore not supplying full fuel.

**Duffman** · 28th August 2011, 07:21 AM

I have checked all the hoses and they are good i set the rockers to 0.20mm.
so if i over adjusted the rockers made the gap to small would that explaine my problem?

**wrinklearthur** · 28th August 2011, 10:18 AM

Originally Posted by Duffman

I have checked all the hoses and they are good i set the rockers to 0.20mm.
so if i over adjusted the rockers made the gap to small would that explaine my problem?

If your proceedure of adjusting the tappets is correct, you should have tappet clearance's set to 0,20mm for both inlet and exhaust.

Cheers Arthur

**Blknight.aus** · 28th August 2011, 11:22 AM

.2 is on the money,

hows the throttle, cable, are you seeing full movement of the throttle link?

**Duffman** · 28th August 2011, 02:45 PM

the throttle link hits the stopper on the injector pump when you put your foot flat.
it went fine befor i touched the injectors and tappets.
it dosent blow any smoke just want speed up my turbo is making just under 1 bar of boost at 2000rpm.

**Blknight.aus** · 28th August 2011, 03:00 PM

ok...

Im going to assume that you didnt do the work yourself or left the vehicle unattended at some point before I ask this.

has someone messed with anything that you're not aware of, like say shifting the throttle stop for max speed as a practical joke?

**Duffman** · 28th August 2011, 06:09 PM

myself one other apprentice did the work and the car was at tafe for the week until my glow plugs arived.
how can i tell if the throttle stop was moved?
i might pull the rocker cover off and redo the tappits.

**Blknight.aus** · 28th August 2011, 08:14 PM

look for freshish tooling witness marks on the lock bolt and thread thats cleaner between the metal of the frame and the linkage.

if you serviced the injectors then you may have set the crack pressure too high (kudos for having a crack at doing it tho, those things are a cast iron bitch of a thing to do) which is going to cost you in terms of injection timing and quantity of fuel injected.

Hows it starting?

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