!!!!!!!!!I am desperate for any ideas here!!!!!!!!!!!!!!

We have a 1987 ford ranger with a 4D55T repower that ran great but leaked fuel at the throttle shaft so I took the pump in for a rebuild and all is not well. The leak is fixed, but the engine just doesn't run right now.

There is a fairly consistent misfire through out the range that gets much worse at idle,

It will only barely idle,

It lopes badly at idle and will rev up and down until finally stalls when the RPM drops. Seems like a governor issue, but I don't know the internals of these pumps.

Smokes pretty badly,

No power

The truck could kick the tires loose before the pump was rebuilt, but now it can't even climb our driveway in high range.

The guy at the pump shop insists all the settings of the pump are in spec.

I took the injectors apart and cleaned them and they have new nozzles- no change

Checked the timing belt position 3 times and it is where it should be. Also tried many different timing positions to no avail.

Valve train is all good, compression good, fuel delivery good. Even tried running the engine out of a bottle to eliminate any potential restriction in the fuel system of the truck.

Like I said, I'm desperate here, if you have ideas at all, please post them!!! <img src="/forums/images/graemlins/barf.gif" alt="" />

Possible air leak? Mine ran like that when I changed the fuel filter and opened the water drain, the o'ring was bad.

Well I messed with the timing a bit more, installed new injector seals and started running it up and down our driveway (steep hill). It gradually got good enough that it would idle but still bumped up and down. Really strange how it slowly got better. But at least it will pull under full load without smoke or missing anymore.

The power is back and the turbo will spool again, but as soon as it drops to idle it starts with the rich diesel stink, blue/grey smoke and poor idle quality.

After messing around in the lot with it for a while it was good enough to drive on the road again. Once on the road it was very nice. Great power, no visible smoke but idleing at stops it would still bump and misfire a little. I fed it some Dex3 tranny fluid and drove it some more and a little harder, its getting better but still not quite there.

Sometimes it will purr like a kitten smoother than I've ever seen before but then it will start to shake intermittently again. Since its drivable again, I'll drive it to the diesel shop that did the work on the pump to see if we can make some sense of what is going on.

Earlier I did try to run the injector pump directly out of an oil jug full of fuel to rule out any potential faults in the fuel system of the truck. The results were exactly the same, so I think the fuel system is good. The filter has only a couple hundred miles on it.

Well he was able to figure it out. When I installed the timing belt I failed to account for a slight amount of stretch and long story short, the injector pump and camshaft were both off by 1 tooth in the same direction.

I starts and idles perfectly even when cold now.

Feeling pretty stupid right about now...... I owe him a case of bud....

I did that when I changed my timing belt...you have to manually pull the injector pump gear over one tooth to get the timing marks to line up when you put tension on the belt. I am glad I started it with everything still off. would have been a real pain if I put the timing covers/belts on and then realized that I did.

Dave,
You say you worked on your injector pump?. I have a 90'ND 2.5tdi. I'm desperate for some guidance to adjust the mixture. you wouldn't have any pointers by chance?
Dex