I'm getting SEVERE injector knock after replacing my well used (12 degrees of stretch) timing chain. It seems that someone adjusted the injection timing to compensate for this chain wear, and is now off.

Anyone know how to adjust it? I ran thru 2 tanks of diesel injector cleaner and no luck, something is messed up.

Let me check with Hans in the next couple of days -- I know it is different than the older ones. You will still use a drip tube, but I think the timing is different, and the bolts that hold the IP in place are in the chain case behind the vacuum pump.

Peter

__________________
1972 220D ?? miles
1988 300E 200,012
1987 300D Turbo killed 9/25/07, 275,000 miles
1985 Volvo 740 GLE Turobodiesel 218,000
1972 280 SE 4.5 165, 000 - It runs!

Thank you sir.

Here's the scoop:

You need a special tool -- I can supply part number, costs my mechanic $245 -- to set the timing. You unscrew a cover plug, and screw in a position sensor. Set engine for 15 ATDC (please note timing!) then loosen the three through bolts on the vac pump that hold the IP on (bolts go all the way through) and then adjust the adjusting nut to get the proper timing (when both lights light up on the test device). There is a little nub on a crossarm at the rear of the pump that does the Hall effect thing with the position sensor.

Needless to say, no special tool, no adjustment.

The good news is that any Authorized Bosch Diesel Service will have the necessary tools (there is also a very nice setup that allows setting the timing with the engine running) and can do the job for you. Check it out unless you feel a strong need to buy the tool.

If you are brave, you can simply loosen the pump bolts and use the adjuster (lock nut and adjusting screw) to rotate the pump in the direction of engine rotation to retard the timing. Better to get it set properly.

Now, the fun part: are you getting smoke at high speed, or at low speed, and do you have any drivability problems? The reason I ask is that you may have been running with very late injection timing, and the engine is simply making more normal noise. Does it sound like someone is using a hammer on the engine or is is just a muffled rattle as though something was loose in the valve cover? The later may be normal until you get the crud burned out from running late timing.

If the timing is really fast, it will sound like an old over the road diesel and "snort" like one when you start it, and under initial acceleration.

Peter

Peter

__________________
1972 220D ?? miles
1988 300E 200,012
1987 300D Turbo killed 9/25/07, 275,000 miles
1985 Volvo 740 GLE Turobodiesel 218,000
1972 280 SE 4.5 165, 000 - It runs!

Thanks for the info but it sounds a bit over my head with needing a special tool.

What I am getting now is a bad, loud injector knock. At idle sometimes it is OK but other times it wakes up the neighbors.

Most times I can hear it driving down the road and even at 60mph. "snap snap snap snap snap"

Also, it sounds as though the engine is injesting more air, kind of hard to explain the sound but it sounds like an exhaust leak of sorts, only no exhaust leak and I didnt have this noise before the chain. Sounds like airflow..

I should mention at the same time I did the chain, I completely cleaned the intake manifold and cross over pipe.

Also, my MPG is down to 21.5 from 23.5, and that number was -very- consistent.

No drivability issuses, except excessive noise, possibly mechanical but I am pretty sure it's injector knock.

Its now been about 1300 miles since the chain. 3 tanks of fuel, 1 bottle of redline and 1 bottle of power service. No difference.

Is it possible to 'eyeball' timing using the locking tool? I mean set the crank to 15 ATDC and rotate the IP until the locking tool engages.

I hope you don't have to reset the IP sprocket.

Sixto
91 300SE
87 300SDL

I'd get it set -- any you should be getting upwards of 26 mpg in town with this car. The 603 is very quiet for a diesel, at least the two we have.

Sixto:

Does the locking tool screw in? If so, it would be difficult to get it so lock on the nib on there, it's fairly small according to the diagrams.

I'd just back the timing off a bit with the adjuster for the time being, until I could get it set properly.

__________________
1972 220D ?? miles
1988 300E 200,012
1987 300D Turbo killed 9/25/07, 275,000 miles
1985 Volvo 740 GLE Turobodiesel 218,000
1972 280 SE 4.5 165, 000 - It runs!

There's some play in the lock tool such that it will engage even if IP timing is not spot on.

Such being the case, maybe TD should see how far off 15 ATDC the crank is when the IP pointer is visible in the special tool/lock port.

Sixto
91 300SE
87 300SDL

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