de_overfiend
13th April 2014, 08:54 PM
hi all
having some major problems with a zd30 that refuses to start unles i feed it start ya bastard.
history:
engine running rough as guts on idle - give it a bit of juice and it was fine but on return to idle it was rough as guts again - replaced fuel filter and some other things to no avail. diagnosed the dual mass flywheel had siezed up so gearbox out and replaced with single mass and new clutch (approx $1500 for parts) couldnt get the effin gearbox back in by my self so tow to the mechanic and $150 later gearbox back in and runs sweet.
small clutch dramas with master - replaced master ($130) and bleed and good heavy duty clutch feel is there.
fast forward about 2 months car is running funny and then overheats. Oil is milky and no water in rad so i diagnosed head gasket. pulled it apart and 5 cracks in the head (1 for each glow plug and big crack between 3 and 4 to water jackets.
Another head from ebay ($1500ish ) and bolted it back together making sure to check timing marks etc (i have a copy of the service manual) and made sure to clean out the filth from the throttle body. Also spent some extra money on a NADS kit. Blocked off EGR and installed dawes and needle valve and new maf. (extra $200 ish). also new fluids and oil filter.
went to crank it over and no crank... found a main earth lead that had been overlooked and bolted it on. primed fuel system manually and cranked it over, bled the injectors and tried to start it. No Go. Killed the battery trying. jumped it a few times on seperate occassions and still wouldnt start.
fast forward another month or so and new $230 battery and a can of start ya bastard. Would slutter and fart but still wouldnt start. re-bled the injectors and the diesel smelt bad. Syphoned the tank and 20L of fresh premium diesel (the expensive stuff) and with intercooler pipe off continual spray start ya bastard while cranking and got it going but would die as soon as you stopped spraying.
After several attempts managed to lean off the ether and get it running well enough to run by itself, jammed the intercooler pipe back on and it runs poorly. brown black toxic smoke from exhaust from the bad fuel but it runs. get it up to temp and managed to take it for a short drive up and down the street to try and clear the bad diesel.poor accelleration and no guts but gets up and down the street fine. let it run for like 30 mins - on idle it is rough and surging. turn the engine preheat switch and ups the idle a bit so it idles higher and only slight surging. Also exhaust is a lot cleaner.
Leave it for a bit while checking sensors and try and start. very reluctant start but it does. Shut it down for the week tinking we just need to do some tuning or iv missed a vacuum line somewhere.
fast forward next week and try again. crank engine and no start. get the trusty can of start ya bastard and with continuious spray it fires unhappily. manage to lean off the ether and jam the intercooler pipe back on and it idles roughly again. fuck around with dawes and needle valve and surging stopped. black death still coming from exhaust. Shut it down and after 5 mins fire it up and it reluctantly starts. checked all the fluid levels and decide to change the oil again to flush the milky bits out. drain it while its hot and leave to drain for a week.
rock up this weekend... oil plug back in and a fresh 8.5 litres of oil in it with a new filter. Cranked it over but wont start. start ya bastard again and it fires up. let it run for a bit and shut it down. try and start it again without start ya bastard all intercooler and turbo pipes done up tight. wont start.
Checked all connectors and rechecked again. removed dawes and needle and run new vacuum lines to respective bits and still no start.
Anyway as u can tell from my rant im kinda over it. it should go dammit. What have i done or what can i check or what could it be.... I dont think the NADS is hindering it from starting... and we havnt toughed the fuel pump. I hear they are like $2800 exchange unit and it was fine before we replaced the head. Iv invested so much time into this thing and i dont wanna give up on it. He's a good friend who iv known for over 15 years and i dont wanna say "well i give up". I kinda feel like i own the problem and i dont want to admit defeat.
Sorry for the essay, but i figured more info the better. Any advice/soloutions would be greatly appreciated. Many thanks in advance...
having some major problems with a zd30 that refuses to start unles i feed it start ya bastard.
history:
engine running rough as guts on idle - give it a bit of juice and it was fine but on return to idle it was rough as guts again - replaced fuel filter and some other things to no avail. diagnosed the dual mass flywheel had siezed up so gearbox out and replaced with single mass and new clutch (approx $1500 for parts) couldnt get the effin gearbox back in by my self so tow to the mechanic and $150 later gearbox back in and runs sweet.
small clutch dramas with master - replaced master ($130) and bleed and good heavy duty clutch feel is there.
fast forward about 2 months car is running funny and then overheats. Oil is milky and no water in rad so i diagnosed head gasket. pulled it apart and 5 cracks in the head (1 for each glow plug and big crack between 3 and 4 to water jackets.
Another head from ebay ($1500ish ) and bolted it back together making sure to check timing marks etc (i have a copy of the service manual) and made sure to clean out the filth from the throttle body. Also spent some extra money on a NADS kit. Blocked off EGR and installed dawes and needle valve and new maf. (extra $200 ish). also new fluids and oil filter.
went to crank it over and no crank... found a main earth lead that had been overlooked and bolted it on. primed fuel system manually and cranked it over, bled the injectors and tried to start it. No Go. Killed the battery trying. jumped it a few times on seperate occassions and still wouldnt start.
fast forward another month or so and new $230 battery and a can of start ya bastard. Would slutter and fart but still wouldnt start. re-bled the injectors and the diesel smelt bad. Syphoned the tank and 20L of fresh premium diesel (the expensive stuff) and with intercooler pipe off continual spray start ya bastard while cranking and got it going but would die as soon as you stopped spraying.
After several attempts managed to lean off the ether and get it running well enough to run by itself, jammed the intercooler pipe back on and it runs poorly. brown black toxic smoke from exhaust from the bad fuel but it runs. get it up to temp and managed to take it for a short drive up and down the street to try and clear the bad diesel.poor accelleration and no guts but gets up and down the street fine. let it run for like 30 mins - on idle it is rough and surging. turn the engine preheat switch and ups the idle a bit so it idles higher and only slight surging. Also exhaust is a lot cleaner.
Leave it for a bit while checking sensors and try and start. very reluctant start but it does. Shut it down for the week tinking we just need to do some tuning or iv missed a vacuum line somewhere.
fast forward next week and try again. crank engine and no start. get the trusty can of start ya bastard and with continuious spray it fires unhappily. manage to lean off the ether and jam the intercooler pipe back on and it idles roughly again. fuck around with dawes and needle valve and surging stopped. black death still coming from exhaust. Shut it down and after 5 mins fire it up and it reluctantly starts. checked all the fluid levels and decide to change the oil again to flush the milky bits out. drain it while its hot and leave to drain for a week.
rock up this weekend... oil plug back in and a fresh 8.5 litres of oil in it with a new filter. Cranked it over but wont start. start ya bastard again and it fires up. let it run for a bit and shut it down. try and start it again without start ya bastard all intercooler and turbo pipes done up tight. wont start.
Checked all connectors and rechecked again. removed dawes and needle and run new vacuum lines to respective bits and still no start.
Anyway as u can tell from my rant im kinda over it. it should go dammit. What have i done or what can i check or what could it be.... I dont think the NADS is hindering it from starting... and we havnt toughed the fuel pump. I hear they are like $2800 exchange unit and it was fine before we replaced the head. Iv invested so much time into this thing and i dont wanna give up on it. He's a good friend who iv known for over 15 years and i dont wanna say "well i give up". I kinda feel like i own the problem and i dont want to admit defeat.
Sorry for the essay, but i figured more info the better. Any advice/soloutions would be greatly appreciated. Many thanks in advance...