Hello all, a couple years ago I swapped out my injector pumps (and injectors) with an entirely new set. I wasn't aware at the time that I had to do the pumps one by one, so I had installed them all at once after removing all of them.
Since then I've had hard starts and overfueling (lots of white/gray smoke, injectors gunked up with soot, engine bay filled with soot). I pulled the pumps off the other day to verify they all were aligned with the rack and that it was moving freely (it was). I googled around a bit and found that the Deutz 1011 motor actually utilizes shims for the injector pump timing. My new set and the old set both did not have shims (as far as I remember). I found online the proper way to find the shim size you need is to take the depth from the tappet at BDC and the deck mounting surface for the pump and subtract it from the depth of the pump's spring/stem. I did that and found the stem/spring is 1mm longer than the depth of the deck/tappet. The measurements were 60mm for the pump and 59 for the tappet/deck at BDC.
I ordered 1mm shims and installed, now the pumps are leaking at the base between the pump and deck surfaces.
I also pulled the injectors to verify they were properly seated and found one had two copper crush washers instead of just one. I remember doing this when I initially installed these injectors as that was how I found it. After re-seating the injectors with brand new washers, two of them now leak. Obviously it no longer is firing/starting.
My question is, is my 873f supposed to even have shims on this 1011 motor? If so, how do I find the correct size? Are they just not tightened down enough? I am pretty positive the injector issue is from not being tightened enough, so that one might be an easier fix.
I recently rebuilt a 404 perkins and I'm just astonished at how weirdly designed this motor is comparatively.
Anyways, what should I do to proceed from here? What should I be checking?
Since then I've had hard starts and overfueling (lots of white/gray smoke, injectors gunked up with soot, engine bay filled with soot). I pulled the pumps off the other day to verify they all were aligned with the rack and that it was moving freely (it was). I googled around a bit and found that the Deutz 1011 motor actually utilizes shims for the injector pump timing. My new set and the old set both did not have shims (as far as I remember). I found online the proper way to find the shim size you need is to take the depth from the tappet at BDC and the deck mounting surface for the pump and subtract it from the depth of the pump's spring/stem. I did that and found the stem/spring is 1mm longer than the depth of the deck/tappet. The measurements were 60mm for the pump and 59 for the tappet/deck at BDC.
I ordered 1mm shims and installed, now the pumps are leaking at the base between the pump and deck surfaces.
I also pulled the injectors to verify they were properly seated and found one had two copper crush washers instead of just one. I remember doing this when I initially installed these injectors as that was how I found it. After re-seating the injectors with brand new washers, two of them now leak. Obviously it no longer is firing/starting.
My question is, is my 873f supposed to even have shims on this 1011 motor? If so, how do I find the correct size? Are they just not tightened down enough? I am pretty positive the injector issue is from not being tightened enough, so that one might be an easier fix.
I recently rebuilt a 404 perkins and I'm just astonished at how weirdly designed this motor is comparatively.
Anyways, what should I do to proceed from here? What should I be checking?
