93 IDI Turbo won’t rev passed 2,000

[dmattera]

Alright, bear with me, this intro is long.

BACKSTORY:
I got the truck in 2018, and it had gotten a new motor around 2016. The motor has about 80k on it based on when I got it and now.

I have a head gasket that finally bit the dust, I’d seen it coming for a while but she held out for a while. No crossing of fluids, just excess pressure in radiator.

In the last 12 months I had pulled my IP to redo a line, and all the return lines. When I reinstalled, I believe I accidentally over advanced my timing. (Didn’t know what I didn’t know. Too late now, I thought it went back in the same spot.) resulted in 100* hitter EGTs, which I took note of, but thought it was related to something else.

I reinstalled the IP just advanced of the static timing line, which is as close to original as I can remember. I plan on either having a shop time it or buy the tools.


FOR THE PROBLEM:
Once the head gasket finally quit, I
Took heads off, new gasket, per the book, new returns, new GPs, nice and sealed up all around. Started the truck, drove it home, and it hits around 2,000 rpm and then just pumps out black smoke and won’t accelerate any faster than 45mph. It also does this in Neutral.

It has a new fuel filter, no leaks, it starts IMMEDIATELY, there is zero cranking, it’s just running when you turn the key. At Idle it sounds beautiful, no knocks, no smoke.

Based on that info, where would you guys start finding issues?

 

[Kdo58]

Did you take off the injection pump and the cover, might have gear a tooth off.

 

[IDIBRONCO]

Another thing to check is if there's any exhaust leaks before the turbo. If there is, you will still be getting all of the fuel to your engine, but not enough air (boost) to burn the fuel.

 

[dmattera]

Did you take off the injection pump and the cover, might have gear a tooth off.

I removed pump by taking off the 3 bolts inside the front of the housing. Left those in the same spot for reinstalling. Would it have been possible to have a tooth off if the pump went back into the same place before I retarded the timing back down to static?

 

[dmattera]

Another thing to check is if there's any exhaust leaks before the turbo. If there is, you will still be getting all of the fuel to your engine, but not enough air (boost) to burn the fuel.

Great idea! I’ll check that, I did have all of that stuff off.

I’m also wondering if it’s fuel filter related, I put a new Baldwin which I’ve never used before. Only ever had wix stuff, it has a much finer micron filtration, I wonder if it can provide the fuel I need?

 

[IDIBRONCO]

Would it have been possible to have a tooth off if the pump went back into the same place before I retarded the timing back down to static?

No. You can have the pump removed and roll the engine upside down on an engine stand and it won't jump any teeth.

I wonder if it can provide the fuel I need?

Since you're seeing a lot of black smoke out of the exhaust, I'd say that you are most definitely getting enough fuel.

 

[Nero]

I removed pump by taking off the 3 bolts inside the front of the housing. Left those in the same spot for reinstalling. Would it have been possible to have a tooth off if the pump went back into the same place before I retarded the timing back down to static?

Nope not possible, at least it wasn't on my 7.3

 

[dmattera]

@Nero and @IDIBRONCO Well.. I took your suggestions and went to make sure my air was all okay and no leaks.

Somehow, and I genuinely don’t know how since I was so paranoid about this..

There was a thick *** of shop towels in the turbo. My only thought is it got into the ATS intake box when I cleaned everything during the HG repair.

Left everything else where it was and took it for a drive. Problem solved, she’s happy as a clam. I have no clue how that happened, and I feel like an idiot, so I figured I’ll come back here and fess up!

Thanks again for helping!

 

[Nero]

Sometimes the best fixes are the siliest. Glad you got er going.