Using fuel, then ruff start up [SOLVED]

[vicszd30]

Howdy all as the post states the zd has been using shite loads of fuel with the last 4 fill ups I would be lucky to get 450k's to 70lts down from the "what I thought was lousy anyway" 550k's per 70lts..

As the zd started using fuel I thought injector/s then last week the ruff starts I thought glow plugs maybe- so I finally got to check the glow plugs today and on loosening the 4th one I noticed it was moving up and down out of the rocker cover seal !
Ok so broken glow plug- thinking its' been running like this "for how long I don't know" and they all have to come out I will run it until warm/hot and "get at 'em"..
Striped it down to the rocker cover off -so I could have a clear look at the glow pluug and see where it's broken at!
Turns out the threaded rod part had come away from the core of the glow plug! "lucky me".. they came out easily and I took the injectors out also whist the zd was warm and they also came out easily, yeayy more luck!

The injectors and glow plugs where all done when the twit* "not Graham" @ w/gull diesel injectors did the timing chain about 10'000k's ago. . The injectors are Zexel and the glow plugs where Bosch..
*left the spill line banjo bolt lose and the motor filled with diesel and made the turbo run-on in the main st of Cowes..yes that twat!

I tested the rest of the glow plugs with a multimeter and unless i'm doing something wrong they are all testing faulty?? Could it start like that??

I will get the injectors tested and fit some new glow plugs up tomorrow and see how "she" fires!

Any suggestions on what glow plugs to use?

 

[Rumpig]

Heaps of info on the patrol forum for glow plugs, they seem to prefer metal over ceramic tips as the ceramic ones can break off. Injectors aren't rebuildable, they can only be tested for crack pressures apparently. Hope you solve your dramas. http://www.patrol4x4.com/forum/zd30-di-engine-3-litre-71/glow-plugs-why-missing-tips-59903/

 

[vicszd30]

Thanks Rum, yeah I know about the injectors- I want to get them tested for "crack pressure" and "spray pattern" ... that's all... Metal for sure - what make was the question?

 

[vicszd30]

Injectors ok new glow plugs.. all I need now is the torqueing down numbers..any help please my manual for the zd motor is packed away and I'm having no luck finding it in the down load manual.. any help . need glow plugs and injector retainer weights please.. cheers vic

 

[tweak'e]

glows 15-19Nm (11-14ftlb)

 

[vicszd30]

All done and didn't that make a world of difference to start up! Runs a lot smother and quieter that's for sure. Not sure if it will help fuel economy but time will tell. The dash light goes off a lot quicker also.
I managed to get a rough idea of the valve clearances and I am going to turn one of the old glow plugs into a fitting for a compression tester so I can see what's going on compression wise..
The glow plugs are easily cut and drilled- here's a pic of the one I have started on..

 

[vicszd30]

Looking at the glow plug that was broken-I believe that what caused it was the use of the wrong nuts! The original nuts have a washer that is attached but free to spin around the nut so when you tighten the nut down the washer prevents the twisting of the glow strap and therefor also the twisting/turning of the threaded rod that the nuts is attached to..
You wouldn't believe the price of each nut !
Makes one wonder what happened to the original ones? Warragul injection service strikes again..
Some how they managed to lose 3 out of the 4 ? I guess I should think myself lucky they didn't end up in the block..