What am I missing?

[Green1]

When I try to start, the glow cycle completes correctly and then I start cranking, it cranks for 1-3 full minutes (spins at 500rpm or so) before catching. It smokes pretty badly at start and then once it warms up it seems reasonably normal, though it smokes under load. re-starting when warm goes smoothly, but once the engine cools off we're back to square one.

I'm running out of ideas, so far I have:
- checked glow system, it applies proper voltage to the plugs and the plugs actually glow red hot when run.
- replaced glow plugs
- adjusted valve clearances
- replaced fuel and air filters
- cleaned EGR valve
- replaced batteries
- adjusted idle to approximately 650rpm
- tightened starter connections
- replaced fuel hoses and checked/tightened all connections

I also had GCL fuel systems in Calgary look at it, they:
- Increased injection pump pressure
- cleaned injectors
- checked injection pump timing
- charged me an arm and a leg

What is left to try?????

[konadog]

IP rebuild perhaps...

[Green1]

IP rebuild perhaps...

GCL Fuel Systems claims it's not needed, however I trust them about as far as I can throw their entire shop....
They told me that the pump is moving fuel and doing it's job right, and that the injectors are spraying fuel at the right time (They say that when they tested the system the timing was advanced by 7 degrees, but that this was a good thing as it gave more power.)
They were EXTREMELY insistent that the problem was with the glow plugs, but I know that even a compression start (where the plugs do NOTHING) isn't as hard as what I have now, I also have personally tested and replaced the plugs.

they quoted me over $1000 just to remove the IP from the engine, that doesn't count for any form of rebuild... (cheaper to drive to CVI!)

[konadog]

The smoke under load won't be related to glow plugs but, I'm told, may suggest problems with the IP - and not just the leaky seal rebuild either, but rather the off to the speciality shop for the $1000.00+ total makeover rebuild. If you decide to spring for it I'm pretty sure ccautos Glen has a few rebuilt IP's on the shelf awaiting a deli in need... Good luck with this issue

[snelson]

hey green, have you checked your compression? With your new head perhaps you've got a bit of valve leak?
just a thought
Steve

[Green1]

hey green, have you checked your compression? With your new head perhaps you've got a bit of valve leak?
just a thought

I have debated it, I'd have to find a shop to do that for me... now the next question becomes, if this is a problem, what can be done about it?

The smoke under load won't be related to glow plugs but, I'm told, may suggest problems with the IP - and not just the leaky seal rebuild either, but rather the off to the speciality shop for the $1000.00+ total makeover rebuild. If you decide to spring for it I'm pretty sure ccautos Glen has a few rebuilt IP's on the shelf awaiting a deli in need... Good luck with this issue

I have thought about this possibility too, of course I hate throwing $1000+ out on a guess... however if I knew for a fact it would fix the problem I'd be on it in an instant!

[Spearo]

Green1 I'm curious how this turned out for you. Mine starts "ok" but seems to take longer than I want it to now that cold is here. I hear of Delicas starting in 1 or 2 seconds after waiting for the single cycle of the glow plugs (2 clicks). I changed the fuel/oil/air filter, put the 5w50 synth oil in, purged the fuel filter. It seems a little better but still....
Any thoughts you have would be much appreciated.
Erik

[Green1]

I've given up.
Since my last post I have had the compression checked (it's fine) I've had the IP rebuilt, I've had the rocker arm replaced, I've had the valves adjusted, I've had a fuel leak fixed, I've cleaned the EGR, intake, and exhaust manifolds... (this is in addition to all new filters, glow plugs, temperature sensor, and batteries as well as extensive testing of the glow plug controller which had been done previously)
The delica has been looked at by 4 different mechanics, including one of the most respected ones in the country. I have spent over $6000 on "fixes" so far in over a year.
It still starts very poorly (at 5c it cranks for 30 seconds to a minute before starting, and not very well at that), it still has very little power, it still smokes horribly, and it still leaks oil badly.

Basically none of the fixes have ever improved anything noticeably, and even then in less than a week the vehicle is back to where it was, and the vehicle is in worse shape now than when I started tackling this problem over a year ago.

I do not plan to attempt any further fixes as I am not going to spend another cent on this engine.

I am currently looking to buy a new Delica, and then this one will be for sale. hopefully someone who is more of a mechanic than I am will be willing to buy it (at a good discount) and try to get it going, but I'm done trying now.

[dfnder]

Does it idle fine after it starts? What about the solenoid which opens the fuel supply? Wondering if the fuel is draining back into the tank.

I'm no mechanic, just things that came to mind.

[Spearo]

Thanks Green1, sorry to hear it hasn't improved >8^(

[Manitoba deli]

Hi there, while I don't have any experience with the l300's, I am a diesel mechanic, and I am wondering if anybody checked the turbo. When the inner seals fail, oil can be pumped into the intake of the engine causing excessive smoke, and extreme difficulty starting when cold. The symptoms are usually worse with synthetic oils, because they are not as combustible as conventional oils. Anyways just my thoughts after reading your posts and all the work done. If you are done with it I'd be interested, I have a l400, but last weekend I looked at Rob's l300 in winnipeg, and I think I need to have one of those too. What a sweet machine.

Jason

[Green1]

Does it idle fine after it starts? What about the solenoid which opens the fuel supply? Wondering if the fuel is draining back into the tank.

I'm no mechanic, just things that came to mind.

No, it idles lousy until it warms up, in fact it will generally stall if I don't keep the revs up to at least 1500 for the first 2-5 minutes.

fuel drainback has been checked by 3 shops, one of which even installed an anti-drainback valve. no difference.

[Green1]

Hi there, while I don't have any experience with the l300's, I am a diesel mechanic, and I am wondering if anybody checked the turbo. When the inner seals fail, oil can be pumped into the intake of the engine causing excessive smoke, and extreme difficulty starting when cold. The symptoms are usually worse with synthetic oils, because they are not as combustible as conventional oils. Anyways just my thoughts after reading your posts and all the work done. If you are done with it I'd be interested, I have a l400, but last weekend I looked at Rob's l300 in winnipeg, and I think I need to have one of those too. What a sweet machine.

Jason

Turbo was replaced already, and I don't have any reason to believe it died again... (I have more power than the vehicle had when the turbo died last time, and less smoke)

[Adrock]

dud glowplugs?

[Green1]

dud glowplugs?

replaced, 3 times, and thoroughly tested along with the temperature sensor (also replaced twice) and the whole system. also doesn't explain loss of power, smoke, rough idle, or even how difficult it is to start (even a sheer compression start is much easier than this is currently)