Archived 97 won't start after gear set case removal

[FFouts]

I removed the oil pan, and gear set cover and case, from front of block to replace the case to block gasket. Engine was moved to TDC, and the pressure pump gear was scribed to the cam gear before disassembly. Two lines were disconnected from passenger side of fuel pump to allow access to pump-to-gearcase bolts. I do not know if I have the harmonic balancer on correctly, nor do I understand the function of the crankshaft position sensor. Engine will crank but not start; there is vaporized fuel exiting the exhaust. Pleas advise...

 

[AKAMAC]

If you are "sure" the timing is correct then your problems may exist with the fuel soleniod. You state that there is fuel vapor from the exhaust... . If this is true I'd make sure pump timing was correct. I'm a 2nd gen guy with a 44 pump. The generators I work with use mech pumps though. Make sure you are not 180° out. Mike

 

[FFouts]

I just went through all 2491 archived posting for clues.

I cracked the fuel line at number 1 and have fuel escaping.

Will the crankshaft position sensor keep it from starting? I am not sure the harmonic balancer was bolted on correctly. I read that pump gears can slip on their shafts? I am going to remove gear set cover again now. The crank-to-cam timing is correct; please explain the possible 180* error? This truck and my parents were to leave for the Rocky Mts. on Tuesday.

 

[ttbird]

your crankshaft speed sensor is really your engine speed(rpm) sensor. The air gap between the sensor and dampener is . 049-. 051 and needs to be gapped with a brass feeler gauge. make sure wires are plugged in to the harness near the front/top of engine.

 

[crabman]

The Engine Speed Sensor just lets the PCM know that the engine is running so the electrical system will charge, tach work etc.

I do not think the EPS would not stop it from running. Correct gap is . 049-. 051(not over notch) using a non-magnetic feeler gauge.

If you are not sure the fuel solenoid is working correctly, you can always wire it up (key on=up position) with wire tie, etc.

I do not think there is a incorrect way to install the vibration damper. (been wrong before)

Good Luck!!

crabman

 

[DieselTweaker]

The sensor will not cause a no start concern.





I would say your pump gear slipped It's not uncommon for this to happen.



And your Damper is fine

 

[FFouts]

Update...

The fuel solenoid is working properly. I cracked 5 of 6 return lines at the injectors and had fuel escape.



I have removed the gear set cover again and the pump gear has not slipped from where I installed it. I scribed these two gears when taking it apart.



The paint marks between crank and cam gears, along with the 0/00 markings in the casting, are aligned.



Are there any markings for pump gear to cam gear alignment?



I understand that balancer position and crankshaft position sensor will not affect starting; thanks for responding.



This truck was running when I shut it down to fix the oil leak.

 

[moparguy]

Me thinks it's Got to be out of time. Make sure #1 is on TDC when checking the gear marks. I had one torn down a couple of months ago and really can't add to what you've already done. Luckly mine started when I bolted all the parts back together.



Since you'er at this point, might as well tab or peen the kdp and bump the timing to 16 or so.



You'll get it started.



Good luck, RR

 

[FFouts]

97 now starts! headed for the Rockies...

The problem was injector pump timing. I was confident that the pump shaft had not moved; I WAS WRONG!



Thanks to all who responded; this was my first repair to any diesel.



A special thanks to a fine member from Logan Ohio who spent 1. 5 hours of phone time talking me through the timing procedure.



I was also introduced to the potential KDP (killer dowel pin) issue and put the preventative measures in place.