OK, I have done this repair again now after over-torquing them the last time.

This time I torqued the delivery valve exactly as prescribed in manuals.

All five were torqued to 30NM, slacked off, 30NM, slacked off and then 35NM for good.

Some of you may recall my previous post where I indicated that I WAY over-torqued them and reused pressure seals to boot.

I got some more seals, o-rings and a torque wrench that would fit in the bay and my results are:

Worse.

It sounds like a 12V Cummins.

It starts easily but smokes grey smoke at startup, generally runs very LOUD and I am guessing that it's not getting enough fuel.

It has even died on me twice shortly after starting the engine.

Also, according to a PDF GSXR posted on another thread it says my idle should be 680+/-20 RPM.

Mine is at least 800, maybe as high as 900 depending, and it has been this way since I bought it 16K miles ago.

A little history since I got the car.

It ran smoothly and quietly before I ran it out of fuel. After that it ran rather roughly and loudly for quite some time.

I noticed along the way that my IP was leaking pretty badly and that the o-rings and pressure seals needed to be replaced.

I did replace them but over torqued the lot before I did them properly yesterday.

Now it runs worse.

I have checked the timing chain and it shows no stretch, maybe 1 degree if anything.

All I can think of now is that I should check/adjust timing.

When I replaced the o-rings and pressure valve seals I didn't remove the internals on which the pressure seal sits.

I just carefully lifted the old copper seal off them and then replaced it with a new one. They did occasionally wobble or shift one way or another in the process but I never lifted them or turned them.

Could I have moved them while torquing the DVs down and if so could this be my problem?

Is there a way to determine this before first determining my timing situation?

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1993 W124 300D
-297K on the clock as I type this.

Is there fuel in all injector lines? With the engine idling, crack each line and look for a dribble of fuel. While you're at it, see if you can isolate roughness to a single cylinder; that is, idle doesn't get worse when you crack the injector line to that cylinder.

Sixto
87 300D

Sometimes it takes a hundred miles or so to settle down. I have never understood why, but it seems to be the case.

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1987 W201 190D

I had heard that so I have been trying to drive a bit around town to speed up the process.

I am probably around 20-30 miles after the R&R so I will keep my fingers crossed.

I haven't cracked the lines at the injectors yet but I will give it a go in a few minutes.

Based on the way it's running, I would think that it's more likely that none of the injectors are getting enough fuel but that's just speculation.

It quietens right up and runs fine at higher RPM's but at idle it's very loud.

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1993 W124 300D
-297K on the clock as I type this.

All the injectors are getting fuel.

I cracked them all one at a time while the engine was running and they all affected the engine equally.

Something else is amiss.

I will keep driving it to see if it improves any.

It could be my imagination but it seemed like it ran a bit quieter after I cracked the lines with it running so maybe a little air was causing some of the problem.

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1993 W124 300D
-297K on the clock as I type this.

Well, it's official, it took me about 200 miles of driving but the engine is now as quiet as ever and the idle even lowered a bit.

The idle is probably about where it's supposed to be now.

Does anybody know why it takes this long for the engine/IP to settle itself?

No word yet on fuel efficiency improvement or lack thereof.

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1993 W124 300D
-297K on the clock as I type this.

Pure speculation but I think even a slight movement of the Delivery Valve while your are removing the spring and related parts moves it from ware it has seated itself over the years.
They seem to need to be drive xxx miles to reseat themselves.

When the pressure drops and your Injector Closes it creates a rverse direction pressure wave. Part of the Delivery Valves Job is to reduce the severity of the wave and sort adjust it so that is happening at time when it will cause the least problems.
This means it has to seal when it is supposed to.

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84 300D, 82 Volvo 244Gl Diesel