4HE1 problem

[Roffe Jingle]

Hello, it’s possible that you have a worn head gasket, and that a bit of coolant is leaking into the oil passages (coolant in your oil) and also into the combustion chamber (white smoke). But yes, I can confirm — white smoke can also be diesel.

Heard you were looking for a mechanic. Unless you go to some 3rd world country where they tear these things apart regularly, that’s going to be tough. I read all 4 pages of this thread and trust me, you know way more than most mechanics regarding this particular engine. I have all the manuals except parts. Let me know if you need something posted.

 

[Roffe Jingle]

Going back to your compression test, my Factory Service Manual (FSM) says minimum psi is about 325 psi or about 22 bar. I think your compression is ok…not great, but ok.

sounds like your pump timing. You saw the Busbee’s video on pump timing. You are aware that when the pump is out, the degrees will be off until you install it because the gears are helical and the timing will move when the pump is installed. Seriously gotta be pump timing.

diesels will also run roughly when out of time so that makes sense. You’ve had the pump out and timed it?

 

[bibabo]

Yes, I tried everything I could without removing the engine. It’s definitely a timing issue, but how did it happen? I only changed the head gasket. After all these tests and thoughts about how this engine works, the only explanation I can see is a misalignment between the small gear and the large gear (page 4). And that happened when I mistimed the camshaft and turned the crankshaft by hand. I found this double gear on eBay, but I don’t know if it’s the right one. I need to remove the engine, take out this double gear, buy the same one, and compare the position of the teeth. If they’re different, then that was indeed the problem.

 

[mekanik]

The fuel pump has an internal timing advance. It could be a problem with it not advancing.

 

[bibabo]

If my theory is correct, only my crankshaft is out of alignment. The injection pump and the camshaft are properly synchronized with each other. So if I adjust the timing of the injection pump, it might become synchronized with the crankshaft, but the camshaft would then be the only one out of sync. Therefore, if I want to restore everything to its original state, I need to replace this double gear, if that's what's causing the issue—there's no other choice

 

[bibabo]

Hello,
Here’s an update.
My truck has been checked by two mechanics, one of whom previously worked for ISUZU. As we had all diagnosed, it really is a timing issue.
My injection pump needs to be set at 8 degrees and not 6 degrees before TDC (it’s even written on a sticker inside the cab).
After many hours of inspections, the mechanics couldn’t find the source of the problem — every component works perfectly on its own, but together, it’s a disaster.
They came to the same conclusion as I did, even though they had never seen this before: the issue might be with the double gear or the crankshaft gear.

I had no choice but to pull the engine out and start dismantling it until I could access this double gear.



I took it apart and removed the ring using a press… but it wasn’t the culprit — it’s a single-piece part.



That leaves as the main suspect the crankshaft gear, which is press-fitted and keyed, and might have slipped by breaking the key — my “klac” sound.
Except I don’t have the proper tool to remove it. I tried as hard as I could, using every method possible to get it to move, but it wouldn’t budge.
I gave up, especially since I think I damaged some teeth and bent other gears while forcing it.

In the meantime, I found a used engine that could be a match.
Mine is a 2003 4HE1-XN, and the other one is a 2006 4HE1-XS.
To make it compatible, I had to remove the EGR, block a hole near the intake, install my new turbo, my alternator, my power steering pump, and of course modify/reuse some water/oil hoses.
I lined the engine up with the gearbox, but they wouldn’t mate. I took it back out and realized it didn’t have the same clutch or the same number of teeth.
So I had to change the clutch and the flywheel, which didn’t have the same dimensions.

I reassembled everything, changed the fluids, bled the system, and turned the key… it started instantly — and without smoke!!!
Just a little blue smoke, but considering it has 250,000 km, that’s normal, I’d say. And nothing compared to my first engine.
For reference, this 4HE1-XS has its pump set to 9 degrees before TDC.

If I find the courage, I’ll cut off the crankshaft gear to see if its key is broken, just to confirm if it was indeed the culprit.
I also need to recover my new cylinder head and all the parts that could be useful to me.
I’ll keep you updated.

See you soon.

 

[mekanik]

I'm glad you getting somewhere with this problem.
I still really think the problem is in the injection pump.