EGTs high, Truck Sluggish: IP banjo filter clogged

204explorer · Post by **204explorer** » Sun Nov 20, 2016 4:02 pm

Glad you found it. Most often it's the simple things like fuel and air supply. I resolved a lot of issues like this by simply blowing air back into the tank.

Sent from my SM-G920W8 using Tapatalk

Post by **Growlerbearnz** » Sun Nov 20, 2016 4:29 pm

OMG so simple. I didn't even think of that screen because the, you know, *fuel filter* should be stopping any crap from the fuel, though I guess the screen's there for a reason.

I'm totally going to clean that screen on my IP. Just in case.

204explorer · Post by **204explorer** » Sun Nov 20, 2016 5:56 pm

Does the 4m40 pump have that screen?

Sent from my SM-G920W8 using Tapatalk

Ralph in Winnipeg · Post by **Ralph in Winnipeg** » Mon Nov 21, 2016 2:03 pm

OMG indeed - so simple and why have a screen AFTER the fuel filter? That's why it was so hard to determine the problem. But apparently stuff gets to there so I'll be putting it back in shortly. I love learning stuff....the hard way! Ralph in Winnipeg

Post by **Growlerbearnz** » Tue Nov 22, 2016 2:34 pm

204explorer wrote:Does the 4m40 pump have that screen?

No idea, but I have the feeling we're going to find out very soon...

Ralph in Winnipeg wrote: I love learning stuff....the hard way!

Murphy's Law says that since you're now confident with repairing the injection system, it'll perform flawlessly for the rest of time.

The gearbox, on the other hand...

Ralph in Winnipeg · Post by **Ralph in Winnipeg** » Tue Nov 22, 2016 4:03 pm

Please don't jinx it! On the upside an acquaintance has a Ram 50 sitting at his farm so I can get parts from it if they fit. There is also a 92 strada that robbie g and I looked at that has a rusted frame that I would consider buying for parts if necessary. Must keep my options open! Ralph in Winnipeg.

ynwa · Post by **ynwa** » Tue Nov 29, 2016 9:15 am

Like howdy eh. I thought I'd just grab onto this thread since I'm banging my head on a similar issue.

First, the little screen that Ralph found, was this located right away once the banjo is pulled? Or does it live inside the pump body, beneath the nut where the banjo sits on? I guess pictures would be better... Anyway, there was no filter or spring once the banjo was pulled.

So here's mine: Same deal, sluggish, high EGT's, LOTS of white smoke at start up and really rough cold starts. Runs like a sack of 'poop' until I can get on the throttle. Stalls 2 or 3 times first...

Tried so far:

> Bench tested all glow plugs. Just 'lit them up', nothing else.
> Bled the fuel filter (seems to pick up air cuz I just primed it a couple weeks ago and managed several pumps this time around.
> There's one injector that looks a bit moist where it enters the head so I pulled that injector and gave it a bit of a cleaning. Nothing obvious visually. But for fun, here it is:

: 20161128_201244[1].jpg (484.28 KiB) Viewed 14664 times

> Then I put everything back together and cranked over the engine until I saw fuel exiting the rail at the injectors.
> Tightened everything back up and after quite a few cranks it sprang to life.
> For about 30 seconds, It sounded like the day she got off the assembly line. Smooth and even and wonderful.

After about 30 seconds something went clunk and she transformed into the same death rattle, smoke blowing heathen that I've been trying to correct.

I'd love a lead on after market Bosch or equiv injectors since OEM's are like $120CAD.

Oh, here's a link to the possessed beast: https://youtu.be/3axufYIVatU

Post by **Growlerbearnz** » Tue Nov 29, 2016 2:28 pm

That's nasty. From your description (ran fine for 30 seconds then started doing... whatever the hell that is...) I'd guess there's a small air leak somewhere. A big air leak would just kill the engine, but a small one would alter your timing before bleeding out* through the injectors.

As a diagnostic step, try pumping the primer pump repeatedly while it's running. In theory if you pump hard enough you'll relieve the vacuum in the fuel lines, eliminate the air leak, and it'll start to run properly again. If that happens you know you've got an air leak.

Check out the (loooong, frustrating) thread in L300 Technical "Suddenly won't start". Around page 4 we get into techniques for diagnosing and eliminating air leaks.

*Phrasing?

ynwa · Post by **ynwa** » Tue Nov 29, 2016 2:35 pm

Growlerbearnz wrote:That's nasty. From your description (ran fine for 30 seconds then started doing... whatever the hell that is...)

Oh, you mean the Smoke Billowing Heathen? Hehe...

Great tip on the pump, I'll give that a try. I certainly went through the 'suddenly won't start' thread, which sounds like it's still going on. Poor guy, ughh...
Thanks again for your insight. WOuldn't that be great to tighten a clamp for the win.

sk66 · Post by **sk66** » Thu Dec 08, 2016 5:51 pm

Same deal, sluggish, high EGT's, LOTS of white smoke at start up and really rough cold starts. Runs like a sack of 'poop' until I can get on the throttle. Stalls 2 or 3 times first...

Sounds a lot like it could be the injector pump shaft seal...

Lapprentis · Post by **Lapprentis** » Sat Nov 25, 2017 7:28 am

I am having that insame High EGT issue

The Cooling system had been adress (New Radiator/Hoses OEM Thermostat, Temperature Sender, Fan Clutch assembly). Timing Belt, Water Pump done recently. I do have between 100-250F hotter than usual (comparing to before and it is winter overhere...

). Almost anything above 80 KPH will show High EGT (blanking plate) in the 900-1100F (in headwind or a very slight climbing). As for the Dash Needle: at idle it will be about a Needle width from the lower whaite mark, at about 800-900F it will be about 2 Needle widh and at 1000F and more (to 1300F) will be about 3X needle width: in any cases, will not get to aim at the thermometer pictogram on the Gauge: I will ease the Gas pedal before....Hard to comment on the Fuel consuption as I make it warm in the morning (winter time here) but seems to be consuming a lot: much more than wha is dripping on the ground...

Any ather thing to look at to cool it down.

I recently saw some Diesel on the ground in the morning: seems to drop from the front end of the Fuel Tank. So I presume I may have some air in the System...Could it be related or it is a "coincidence" ?

Thanks

Lapprentis

Lapprentis · Post by **Lapprentis** » Wed Nov 29, 2017 1:18 pm

Hallelujah! Issues resolved! There was a hidden little screen in the fuel supply line right at the banjo fitting before the IP that was totally clogged. Such a simple thing and yet so hard to find! Truck is running better than ever, EGTs on the highway below 200C. Pretty relieved

Can someone post a picture-drawing of that area with an Arrow/Circle of some kind so we know where is Banjo Fitting ? I will give it a look

Lapprentis

AKcub · Post by **AKcub** » Wed Nov 29, 2017 1:34 pm

Edit- bad information. Disregard.

: VE-plunger.jpg (57.65 KiB) Viewed 14100 times

Lapprentis · Post by **Lapprentis** » Wed Nov 29, 2017 2:03 pm

Delete unrelated picture

Post by **Growlerbearnz** » Thu Nov 30, 2017 1:32 pm

The screen you need to worry about is in the outlet banjo on the back of the IP (not pictured in the diagram above):

: OUtlet.JPG (74.5 KiB) Viewed 14075 times

: Screen.JPG (357.1 KiB) Viewed 14075 times

The outlet banjo has a tiny port, intended to restrict the flow of fuel so the injection pump is slightly pressurised. The injection pump uses that internal pressure to regulate the timing.

: Restrictor.JPG (67.09 KiB) Viewed 14075 times

If the screen or port are clogged, internal pressure will rise, which changes the timing.

The screen on my pump doesn't appear to be removable, unlike Ralph's screen:

Ralph in Winnipeg wrote:

IMG_0429.JPG (32.82 KiB) Viewed 14074 times

Here is the culprit. I'm thinking of putting it back in - it worked once and may need to stop some crap again. And now I know where it is.

If I had to clean it, I would apply compressed air to the restrictor port while aiming the screen end at a sheet of clean paper. That should shift anything that's in there, and let you see if anything comes out. If something comes out, I would flush the banjo with diesel and apply compressed air again- repeating until nothing came out.