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Diaphram, and Star wheel

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Last weekend I was out looking at my pump after reading in the archives about the Diaphram and start wheel and decided to do a little adjustment. Old School had great info about the Diaphram and how it works. His post said to turn it from 12:00 o'clock to 3:30, with 12:00 being at the top of the Diaphram by the valve cover.

Upon reading more and removing the diaphram, it is easy to see that the shaft is "tapered" and non concentric as you move down the shaft. Think of it as being shaped like a Dunce cap, but with one side or area of the cap being "shallower" than the other. I know this sounds totally ridiculous but you will need to have the wording out there with you when you are looking at it. Inside where this shaft sits is a pin that moves in and out as the throttle is engaged (you give it the gas). This pin is on the same plane as the crankshaft. With the diaphram out, move the throttle and the pin should come out. You can push it back in gently with a small screwdriver. Now realize that the diaphram shaft being tapered has a "shallow" side and a "deep" side ( I know it is not square but work with me here on this one). To get the most affect from moving the diaphram, turn it so that the shallow side of the shaft is pointing towards the pin that comes out as you engage the throttle. You want this pin to be able to move as much as possible to get the most fuel flow. I found mine to be set at almost the maximum "deep" side of the tapered shaft, thus limiting the pin movement to minimal travel and decreased fuel flow. I also turned the star wheel (which sits under the diaphram) clockwise one turn. I also, based on old schools writings, went two turns in on the smoke screw (located under the tamper proof metal cap). I get just a whisper of smoke on start up where as before I would get a nice little cloud whether the engine was hot or cold. I did not have time to test another half turn on the start wheel but will later.

Realize that my truck has the stock 21cm turbine housing, but boy did this little adjustment wake up the old ghost!!! It actually will break the tires loose from a dead stop with a little power brake. I have a 16cm housing sitting in the garage but not enough time to get it on (I know, I know excuses excuses). My PW injectors are also still in the box next to the Turbine housing ddddddooooooohhhhhhhhhhh!!!!!

I hope no one takes this explenation as an Algore talking down to you explenation, but until I found the info in the archives and printed it out and had it as reference while working all the explenations did not make sense to me. I'm not the sharpest knife in the drawer, but fairly lethal with good instructions!!!!! Hopes this helps.

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92 Ext. Cab, Auto trans. , 3. 54 Non-LS, Isspro Tach and Pyro (pre-turbo), 210,000+ miles, straight pipe,old and abused but still running strong!!!!

[This message has been edited by Shrimpy (edited 12-03-2000). ]
 
Also worth noting is what i learned from Piers at BD. ( I hope i get this rite Piers, you tried sooo hard)
The star wheel will affect your fuel and smoke from low to mid range. Your 'full power fuel adjustment' is a bit misleading. It does increase the amount of fuel you get at WOT BUT! of the total amount of fuel increase caused by adjusting that thing, more of the fuel increase will be sent to the lower end of the power band. (did i get that rite Piers??) so for example if you increase fuel by 20% then eg: 12 or 13 of 14% will go to lower end with balance directed toward WOT position. NOTE i just made up the numbers to illustrate my understanding. I have found working with the diaghram and star wheel to be the most productive since talking to Piers. It takes some tinkering to get response/smoke etc. the way you want it.

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93. 5 D250 4X4,HD Spring Pkg, Rancho 7000's, Rear Swaybar, Dual Shock Front Stabilizer, BD Injectors, 31/2" Mandrel bent exhaust, 16cm 'Hot End', Modest Pump Tweaks/Timed, K&N Air, Isspro Pyro,Tach,transmission Temp, Auto Meter Oil Filled Boost Ga. , 3:54's, 4 Speed Auto, Clubcab, Aftermarket Reclining Buckets w/ctr Drop Down seat/console, Black over Silver, 21psi,285-65R-16's,American Racing Clear Coat Mags, Amsoil 15W-40HD Marine,12,000 lb. Warn Winch,KC Spots.
97,000 Kms.
 
Bushwkr, I agree. I have not messed with the full fuel screw because I was so impressed with the adjustments in the star wheel and diaphram. I am going to be doing some more fine tuning in the next day or two. I have gone in one full turn on star wheel (clock wise), turned diaphram for max pin movement, and two turns in on the smoke screw. I get very little smoke at W. O. T. and just a small puff at start up. This leads me to believe that I can adjust some more, at least 1/2 to one full turn more, on the star wheel and see what the smoke does.

Good info here, hope others can make good use of it!!!!

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92 Ext. Cab, Auto trans. , 3. 54 Non-LS, Isspro Tach and Pyro (pre-turbo), 210,000+ miles, straight pipe,old and abused but still running strong!!!!
 
I got an email from Piers along time ago stating what you guys said about the fuel screw loading more in the low RPM band and the diaphram/starwheel for the higher RPM fuel control.
Have you guys removed the collar on the fuel screw or are you at stock settings? I haven't done this yet for fear of torching the engine (no intercooler).

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Jason Hoffman
Lil' Mack - 89 D250LE 5 Spd 3. 54 Reg Cab. K&N,"tweaked pump", BD Injectors, Banks Pyro/Boost, 3. 5" Exst tail section straight. E&M Custom seats. Bosch H4, PIAA 80W/80W HdLites. 100W Drv,55W Fogs. 237,500 miles (380,000 Kms) 7850 Hrs.
Cummins Power Booster member.
The Original Turbo Diesel

Lil' Mack Pics
 
You guys got it right #ad
you're gonna put me out of a job #ad


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Piers, BD engine R&D

[This message has been edited by Piers (edited 12-04-2000). ]
 
Piers, by the time we put you out of a job we'll all be too darn old to know it, or care.
As to the lock collar, no I have not removed mine. I have found that if I want to get crazy there seems to be more than enough room to do that without removing the thing. I have tuned the fuel power setting back a bit and worked with the diaghram and star wheel recently. (since talking to Piers) in fact I may turn the FPS (full power screw) back a bit more yet and work a bit more with the star wheel and smoke adjust to see what the overall effect is in going just that route. I have not seen any significant temp. increases in doing any of this. It has made a 'tiny' bit of diff. but not enough to even quote here. I have never seen over 850* post turbo anyway. I do need to load up with some weight and check again since installing the BD injectors, but I'm not expecting anything radical. I'll let you know how it goes.
The one thing that really shocked me was what the transmission oil temp was directly exiting the TC. If you get on it hard, that puppy climbs pretty quick... !

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93. 5 D250 4X4,HD Spring Pkg, Rancho 7000's, Rear Swaybar,Dual Shock Front Stabilizer,BD Injectors,31/2" Mandrel bent exhaust,16cm 'Hot End',Modest Pump Tweaks/Timed,K&N Air,Isspro Pyro,Tach,transmission Temp,Auto Meter Oil Filled Boost Ga. , 3:54's, 4 Speed Auto, Clubcab, Aftermarket Reclining Buckets w/ctr Drop Down seat/console, Black over Silver, 21psi,285-65R-16's,American Racing Clear Coat Mags, Amsoil 15W-40HD Marine,12,000 lb. Warn Winch,KC Spots. 97,000 Kms.
 
I have been following with interest the TDR discussions on VE pump adjustments for some time. So I decided to do a search on the topic with the view of perhaps tinkering a little with the pump on my 92.

Spent the last couple of days searching and reading VE pump adjustment postings and articles and came up with quite a number of them, but found the following the most helpful:
Ram Diesel Power Increase
Fuel Pump Adjustment
Plunger Adjustment
89-93 VE pump adjustment
Diaphragm and Star Wheel
16cm Turbo Housing
AFC Star Wheel
Super hot pre 93
Full Load Fuel Adj. - "Old School" you out there?!

It is my understanding from some of the posts that the VE pump isn't capable of pushing much more fuel than it does. This may be a silly question, but my question is, both the power adjustment screw and the diaphragm adjustment (12:00 to 3:00 o'clock) deliver more fuel, is one harder on the pump than the other?

Am I correct there are at least 6 possible adjustments on our pumps?
1) Timing
2) Idle Screw
3) Fuel Delivery Rate (Smoke Adjustment Screw)
4) Diaphragm Adjustment
5) Star Wheel Adjustment
6) Full Power Adjustment Screw


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Al
 
Excellent post Al!!! These are the same posts I was refering to, just did not take the time reference them as you did. I installed the 16 cm housing back on Monday, but without the injectors did not notice a large jump in S. O. P. (seat of the pants) dyno.

I am now experiencing a strange noise when ever I shut down the engine. It is a metalic sound coming from the turbo somewhere. What is more perplexing is that I was EXTREMELY careful removing the old housing, took me over an hour to tap it loose using a circular path around the housing and a rubber hammer. Also the turbine wheel spins freely when spun by hand and makes no noise. Also when you remove the intake hose and start the truck and watch the shaft spin you can detect no out of round problem. When the truck is shut down it takes approx. 25 sec. for the shaft to spin down from idle. The shaft does not have any side to side or up and down movement. Have experienced no lose of power or any increased amount of smoke.

I removed the turbo again and inspected both the exhaust and compressor sides for any contact but found none. I cleaned under the bearing heat shield beneath the exhaust wheel side. Yet the sound is still there on shut down for approx. 8 sec. I have continued to drive with no adverse problems or increase in the metallic sound at shut down. Anyone have any suggestions ?????

Thanks

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92 Ext. Cab, Auto trans. , 3. 54 Non-LS, Isspro Tach and Pyro (pre-turbo), 210,000+ miles, straight pipe,old and abused but still running strong!!!!
 
Shrimpy, I did the same instal about a month ago without any problems. Check to see that no exhaust is blowing out where the down pipe hooks up to the turbo - just in case it is blowing on something that causes the noise.
Good luck,
Al
 
Thanks Al, I have been all over it and found nothing leaking that I can tell. I spoke with what seemed to be a fairly knowledgeable Turbo man this morning and he said that it sounds like a bearing retainer (?????) going bad. The way he explained it was that there are brass retainers on either side of the bearing on the exhaust side. He said that even with slight tapping to remove the old housing that a piece of carbon could have broken loose and become lodged in this area. He said that with the milage I have (220,000 ++) this would not be uncommon. However, without looking at it he could not say for sure. I plan to remove it tomorrow and take it to a shop in here in Houston.

Thanks... ... ...

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92 Ext. Cab, Auto trans. , 3. 54 Non-LS, Isspro Tach and Pyro (pre-turbo), 210,000+ miles, straight pipe,old and abused but still running strong!!!!
 
FWIW,,, being the slightly wussy type when it comes to changing things I gave the methodology for changing the turbo housing some thought. I decided instead of the taping,smacking,beating, and swearing method I would do the following...
All you need to do is place a solid object such as a metal block/spacer between the housing bolthead and the compressor casting and then back the 4 bolts out slowly, alternating in an X fashion. This had the effect of using the leverage of the bolt threads to do the work. It went great! The stock housing just popped off slick as goose poop (synthetic of course).
I had no need to even threaten it with a hammer or other object of violence.
Just a thought guys.

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93. 5 D250 4X4,HD Spring Pkg, Rancho 7000's, Rear Swaybar,Dual Shock Front Stabilizer,BD Injectors,31/2" Mandrel bent exhaust,16cm 'Hot End',Modest Pump Tweaks/Timed,K&N Air,Isspro Pyro,Tach,transmission Temp,Auto Meter Oil Filled Boost Ga. , 3:54's, 4 Speed Auto, Clubcab, Aftermarket Reclining Buckets w/ctr Drop Down seat/console, Black over Silver, 21psi,285-65R-16's,American Racing Clear Coat Mags, Amsoil 15W-40HD Marine,12,000 lb. Warn Winch,KC Spots. 97,000 Kms.
 
The postings regarding the diaphragm and star wheel adjustment along previous postings dealing the VE pump adjustments are excellent. I agree it hard to understand the posts unless one reads them a number of times and gets up enough courage and goes out and does a little tinkering with the old pump. It now makes a heck of lot more sense.

I found that the diaphragm had already been rotated by approximately 90 degrees. I turned up the power adjustment screw by 1 turn, but found even after trying to adjust the smoke screw that it was still smoking too much so I turned backed the adjustment screw.
I also now understand the frustration that some of you expressed with the locknut on the idle screw - I followed some elses advice and used a fairly long punch to gently loosen the lock nut - works like a charm.
---
Al

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92-LE,4x4,5spd,3. 54,Borgeson steering shaft, Tach,Isspro Pyro & Boost, 16cm2, PW injectors
 
Al,
I was trying to get the nut loose on my pump the other night and finally gave up. Ever since I put in the PW injectors I've needed to turn back the idle. Did not think of using a punch. Guess I need to look more in the achives when I have a problem like that. Thanks for the info.

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Stan
93 2WD extended cab, Banks Power Pack, K&N Air Filter, PW Injectors,Auto w/4. 10 rear with limited slip, US Gear Exhaust Brake, 31/2" Exhaust, 5K air bags, Boost/Pyro/Tach Gauges, Green/Silver, new 40-20-40 bucket seats, 149K
 
What I ended up doing is using a 10mm deep socket (1/4" drive)and the little extension
used to attach it to a screwdriver or ratchet. This extension is about 1 1/4" long and fits into a 1/4" drive end on the socket. Leave off the ratchet and use a 1/4" combo wrench to slide over the other end of the extension. This is just long enough to clear everything but not so long that you can't get a grip on the little bugger. You may find that when you've done the adjustment and go to tighten up the nut again it will 'drag' your adjustment up a bit, so watch that and don't make the final 'tighten up' till you've double checked the idle. It worked for me. Still, its a pain in posterior quarter panel.
Hope this helps, atleast it may be better than striking the nut with a punch.

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93. 5 D250 4X4,HD Spring Pkg, Rancho 7000's, Rear Swaybar,Dual Shock Front Stabilizer,BD Injectors,31/2" Mandrel bent exhaust,16cm 'Hot End',Modest Pump Tweaks/Timed,K&N Air,Isspro Pyro,Tach,transmission Temp,Auto Meter Oil Filled Boost Ga. , 3:54's, 4 Speed Auto, Clubcab, Aftermarket Reclining Buckets w/ctr Drop Down seat/console, Black over Silver, 21psi,285-65R-16's,American Racing Clear Coat Mags, Amsoil 15W-40HD Marine,12,000 lb. Warn Winch,KC Spots. 97,000 Kms.
 
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