just aint right...

[TRENDZ]

I traded my 90 non ic truck, in nice running condition(but extreme rusted condition) with 160,000 miles- for a poor running 91 non ic dually a few years back. I wanted the dually(159" cab/chassis) for stability while towing.
When I got it, it had a single cylinder mis-fire. I really had no reservations about the engine, as the original plan was to freshen the head(valve job and some minor port work) new gaskets, turbo, nozzles, a little pump tweek etc...
After getting it home, I found that #3 cylinder was dead by cracking injector lines. I took off the rocker cover, and found a bent exhaust pushrod. Before tearing down the engine, I put a pushrod in it. The mis-fire was gone, but the engine was not as smooth as I was used to with my previous truck. I assumed I would find some issue with the tear down.
Anyway, after having the head done, 60# springs, rebuilt stock nozzles, adding a 2nd gen intercooler, 3" tubes, 351 turbo, 4" exhaust, larger supply lines all the way to the pickup in the tank, piston lift pump, new fuel pin, turned fuel screw, and doing the KDP, The truck still doesn't seem fast, even compared with my previous "almost" stock truck. It also is not smooth at idle like my old truck. There is no way it would spin the tires, even when the fuel is maxed and making 35psi boost. just aint right...
It really falls flat(and even sounds strange) when really getting into it. The smoke is heavy, but very grey, not black.
Doing a poor man's cylinder balance test seems to indicate all cylinders are equal in power.
When I did the KDP, the pin was missing, and a few of the gears had marks in them of something(pin) striking them, although the timing marks all still lined up. In fact, I spun the engine a few complete rotations to be sure that the gears spun true. Everything appeared fine. The problem is, I suspect that the crank gear is out of time. It's been so long, I can't remember if I checked that. I've been hearing more and more about shearing the crank pin. I've seen pictures of varying degrees of shift when it happens.
Bottom line, here are my symptoms:
poor starting
rough idle
poor mileage
less than expected power
grey smoke under power
definite sound change and power/ smoke at hard throttle
I suspect the pump and cam are in time with eachother, but the crank is out of time with them. I also suspect that the injectors are spraying outside of the bowls in the pistons when I get the sound/ power change.
So what do you guys think? I'm open to theories here!
I'm sure I'm leaving out alot of the things that Ive checked, but I defineitely missed something with this one. My truck should be much more powerfull and smoother than it is.

[RCCUMMINS89]

Is it smoking at idle? If so, what color? Does it idle down a lot after it has been running hard?

[TRENDZ]

at idle warm, no smoke.
idle speed stays constant no matter how hard it is run.
I had the pump apart last summer to see if I could find any issues. The pump looked like new. even the h&r.

[RCCUMMINS89]

Sounds like either compression or injectors to me..... But there a couple variables that say otherwise.

Boost leak?

[Tacoclaw]

Is the KSB hooked up right? You're going to be looking at less power regardless comparing an IC'd truck to non-IC'd, but the spraying out of the bowls is an odd circumstance. If the timing slipped, it would retard, which would put it in the bowls.

I know my truck idles like hell when the KSB isn't working right.

[TRENDZ]

No boost leak. I checked that last weekend with a 3" plug with 15 psi regulated air pressure at the turbo outlet, so the tubes, intercooler and intake plate are all sealed.
I would think the compression would be terrible with the crank past tdc when the cam timing wants it there.( if it is out of time)
Always wondered why it had a bent pushrod also... and why if it is slipped why I don't have 6 bent pushrods.
The ksb is working right. Cold mornings I get a "sharp" sound from the engine until the ksb warms, then normal sounding timing. in either condition cold or warm, the idle is not smooth.
both trucks were/are originally non ic with added ic.
I'm not saying that it IS spraying out of the bowls, I just suspect that it may be. I would think that with the crank advanced(in relation to the cam and pump) that when the pump's timing advance goes full, combined with the over advanced crank, that it could be,but I could be way off base with this idea. Thanks guys keep the ideas coming!

[ellis93]

The bent push rod may just have been from someone revving the piss out of it. It happens. I would almost bet its in the pump.....even tho you were in it. Reason I say that is you (nor I or any other regular Jo) have no capabilty to measure it's out put. At idle it might just be two weak to give the apropriate amount of fuel or there may be a delivery valve stuck or something. I'm no expert tho and just brain storming

[TRENDZ]

I got this truck from a delivery company. The pump had all the tamper caps on it. I would think that you could get in this thing and put your foot to the floor in stock tune, with the thing in neutral, and never be able to overspeed the engine- but anything is possible.
As far as the pump.who knows. I agree with you that the average guy doesn't have the equipment or expertise. I'm just stuck on the fact that this thing doesn't seem right under any condition. It can make over 30psi, and smoke- yet have no real power. I would like to try another pump, but it seems almost more difficult than just opening up the timing cover.
Can you guys tell I'm convinced its timing Thanks!

[TRENDZ]

opened it up tonight. The gear is almost where it should be. the pin is slightly deformed and the gear slot is the tinyest bit open on one side. I would say it's les than 1/4 of a tooth out from where it should be. In my mind, not enough to have the effects I'm having.
I think the next step is to have the nozzles checked by someone other than where they came from for spray pattern/angle. after that I suppose its time to spend the bucks and have the pump gone through by someone that really knows these things.