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Squiggle Dog · #10 01-08-2015, 08:56 AM

I removed the injectors and could see that the #2 cylinder was full of diesel purge. So it was hydrolocked. I'm not sure about the other cylinders, but the #2 was near the top of its stroke, so that one was obvious.

I cranked over the engine and it turned freely, shooting out diesel purge all over. So, at least the engine is not seized. But now I have to figure out where the malfunction is, or if it's just the way I had bled the system with the stop lever wedged in full flow and not having all of the lines cracked at the same time.

I know that the injectors are closed until a certain fuel pressure (like 143bar) is reached, which causes the spring inside to yield and fuel sprays out. If there was dirt in an injector, and it was stuck open, then fuel would be constantly drizzling or spraying out, but I don't think the volume would be any higher than normal because that is regulated by the pump.

Maybe I messed up something when I replaced the O-rings and crush washers in the delivery valves of the pump. When I put the bodies back in, they all were exactly the same height and I torqued them in 3 stages.

The coolant in the expansion tank is still full and I see no traces of oil. The fluid in the crankcase smells like diesel purge and is the same consistency. It doesn't look anything like coolant, which would make the oil a milky color. The diesel purge was inside of the intake and exhaust manifolds as well. Some of the diesel purge got blown into the manifolds, and some got blown into the crankcase. And some stayed in the cylinders. The tank that was holding the diesel purge still looks clear.

In short, I have to determine if the fuel pump is functioning properly. Then I have to determine if the injectors are functioning properly.