Bringing non-runner M1165A1 REV back to life!

[Mogman]

During the takedown process of removing the power steering reservoir, intake manifold, turbo crossover, etc I noticed some damage to the engine harness, including the main ground wire (3C) as well as the three wires to the TPS (Throttle Positioning Sensor). The TPS wires were severed completely. Would a disconnected TPS cause the rough idling in the video I posted above? Wondering if that's been my culprit all along...

Not likely, there is nothing electric about the engine but for the shut down solenoid.

 

[GMVguy]

Welp.... found the problem: https://youtube.com/shorts/oQPNdCx3f98?feature=share

Don't think there's a fuel additive that can fix this issue.

 

[Mogman]

unfortunately that is all to common

 

[GMVguy]

That’s what I’m hearing… Recommend any IP rebuilders that I can send this to?

unfortunately that is all to common

 

[tomelroy]

DIY on the pump rebuild. ( youtube university if needed) Might get luck by just taking the bottom end off and cleaning it up.

 

[GMVguy]

DIY on the pump rebuild. ( youtube university if needed) Might get luck by just taking the bottom end off and cleaning it up.

Would love to, but I hear special tools are needed for calibrating it. But yes, if rebuilding the bottom end fixes it, that would be great! Turns out this is not a Stanadyne IP, but is an AMBAC Model AB5079R. Know where I can find the rebuild kit for it? At least for the bottom end (replacement plunger shaft, etc).

 

[tomelroy]

Try DCP 901-343-6453, but I would cover the inlet and outlets and wire brush or soda blast the case...get it clean... then take the 2 side caps off, then the bottom bolt, see if you can clean what you have up or if its needs replacement parts.

 

[Retiredwarhorses]

Try DCP 901-343-6453, but I would cover the inlet and outlets and wire brush or soda blast the case...get it clean... then take the 2 side caps off, then the bottom bolt, see if you can clean what you have up or if its needs replacement parts.

DO NOT USE DCP….worst pump rebuilder in the U.S.
just buy a new or rebuilt from HPG or MAC

 

[tomelroy]

DCP sells parts …your pump works, but you light load advance is stuck. Could be a simple fix.

 

[tomelroy]

Mac 1,800.93, HPG 1,599.99(on sale now)

the plunger is 12.00, seal kit 59.00 you can even get just the seals for the caps and the light load piston if needed.

22917 Pin
27163 pin seal
32982 cap seal

Baker Diesel 801-731-2921. They will ship and great to work with.

 

[GMVguy]

Got the new pump in and now moving on to replace the fuel injectors. Has anyone figured out a way to replace the driver-side injectors WITHOUT removing the 400-AMP Alternator on these REVs? I have gorilla hands.

 

[GMVguy]

You know that special feeling of hope & fear when you complete a big job and are about to start up the truck?
You take a drink of an iced-cold beverage as you triple-check EVERYTHING, pause a second and turn the ignition?
Well, it didn't blow up, but it did give me a big womp-womp... blowin white smoke everywhere.
Feels like I'm back to square 1 (symptom wise) but after all this, I have to be close!!! (video link below)

Here's a recap of what I've done so far (in order):

1. New Batteries
2. New Glow Plugs
3. New Nartron S3 Start Box
4. Replaced fluids/filters
5. Removed/Bypassed fuel check valves
6. Drained & Filled Fuel Tank w/fresh fuel
7. New fuel filter element
8. Verified compression on all cylinders (good)
9. Manually checked oil pressure (good)
10. Replaced Injection Pump (fresh rebuild), lined up & installed
11. Replaced all injectors, bled lines
12. Fires right up, runs rough and blows white smoke!

Video of startup:

If you have any recommendations on where I can go from here, I would appreciate the wisdom!

 

[Retiredwarhorses]

You know that special feeling of hope & fear when you complete a big job and are about to start up the truck?
You take a drink of an iced-cold beverage as you triple-check EVERYTHING, pause a second and turn the ignition?
Well, it didn't blow up, but it did give me a big womp-womp... blowin white smoke everywhere.
Feels like I'm back to square 1 (symptom wise) but after all this, I have to be close!!! (video link below)

Here's a recap of what I've done so far (in order):

1. New Batteries
2. New Glow Plugs
3. New Nartron S3 Start Box
4. Replaced fluids/filters
5. Removed/Bypassed fuel check valves
6. Drained & Filled Fuel Tank w/fresh fuel
7. New fuel filter element
8. Verified compression on all cylinders (good)
9. Manually checked oil pressure (good)
10. Replaced Injection Pump (fresh rebuild), lined up & installed
11. Replaced all injectors, bled lines
12. Fires right up, runs rough and blows white smoke!

Video of startup:

If you have any recommendations on where I can go from here, I would appreciate the wisdom!

using rebuilt pumps literally leaves open the higher possibility the issue is the rebuilt pump, unless it was doing same with old pump.

 

[GMVguy]

The white smoke was happening before all the repairs, and it was running a bit rougher. I wonder if now, the white smoke is from purging water and old fuel out of the system… Is there a chance it clears up if I let it run For a while to get to operating temp? Can’t think of anything else to replace…

 

[87cr250r]

I tried to rebuild my own injection pump once. The engine ran exactly like that afterwards. It ran fine before, hard to start due to throttle shaft leaking. It ran fine again with a different pump.

 

[Retiredwarhorses]

The white smoke was happening before all the repairs, and it was running a bit rougher. I wonder if now, the white smoke is from purging water and old fuel out of the system… Is there a chance it clears up if I let it run For a while to get to operating temp? Can’t think of anything else to replace…

There should be no water in the fuel or old fuel…you should have drained the fuel tank and added fresh fuel.
The rough idle can be easily be air still in the system, the white smoke can be a bad injector, a bad pump, low compression etc…
this is why I don’t “shot gun“ a host of new parts when I’m doing fuel related issues, injectors especially, but injectors usually have a tell tale sign of knocking terribly if stuck…did you install the correct injectors? Where did you source them?

 

[tomelroy]

Did you check compression on every cylinder? looks like white smoke out of the intakes (but not all of them?). Whats coming out of the exhaust? Did you check the cat? Is it plugged? Remove the section of exhaust from the turbo to the cat and let it run...any better? If that cat looks good maybe timing?

I always remove that section of exhaust and run a camera down the pipe to the front side of the cat to inspect it...

 

[Mogman]

Did you check compression on every cylinder? looks like white smoke out of the intakes (but not all of them?). Whats coming out of the exhaust? Did you check the cat? Is it plugged? Remove the section of exhaust from the turbo to the cat and let it run...any better? If that cat looks good maybe timing?

I always remove that section of exhaust and run a camera down the pipe to the front side of the cat to inspect it...

That smoke is coming out of the exhaust ports in the heads, They are a left over from the gasser engines to pre-heat the intake manifold.
So much can go wrong by running an engine with the intake off I would never attempt it.