2.1dj Inj Auto - rough running after re-assembly

[munkeyh]

Hi folks, I'm looking for some advice or someone local to Loughborough to take a look at my van please.

Its the 2.1 fuel injected automatic. Having put the engine back together, its running a little lumpy, from the exhaust note it almost sounds a bit poppy, like its not running cleanly on all cylinders. If I can get the video I took uploaded it might help. I also feel like its getting hot fairly quickly. That said the temp gauge sits over the red light and the cooling system is doing its job and it not overheating.

This is my first van and engine rebuild so I don't have a great deal of background.

I've rebuilt the bottom end - long story, but I got the engine already disassembled, due to a broken piston ring and damaged piston. I had the crankshaft and camshaft checked by a local engineering company. I've fitted new pistons, liners, rings, gudgeon. New mains, big end and small end bushes. I also replaced the hydraulic followers as whoever stripped the engine muddled them up. The engine had only done around 65k so I didn't touch the top end apart from cleaning up the valves and lapping them back in.

I've also got new plugs, leads, coil, dizzy cap and rotor arm.

Throttle switch is adjusted.
Idle is nice and steady.
I'm running Tesco Momentum unleaded. I've set the timing to the v notch on the 3 groove pulley (power steering model).
I've change the fuel filter, fuel pressure looks ok and I have a cone of fuel from each injector. I don't know where I am from a mixture/CO perspective and I have no way of checking.

I've checked compression (engine warm, throttle open) and I have the following:
1 150psi
2 155psi
3 145psi
4 160psi

Are these differences significant? Maybe a little low for the high compression engine? Would they likely improve as i run the engine in?
Or could this be one of my issues?

I'm hoping for some easy things to try I've not thought of. Or worst case do I have head gasket sealing issues?

The kids are getting bored of watching me standing over the engine bay scratching my head so I'd appreciate some advice.

Are there any video sharing sites I can use to share the video?

Cheers
Mark

[itchyfeet]

did you disconnect vacuum when seting timing?
compression may be low until it runs in but mine were all 13.5 ish bar 195psi after a few hours of running.

[Mocki]

I have a cheap and nasty gas analyser here in mansfield if you want to check what coming out of the zorst .
Does sound like it maybe a ignition timing thing tho....

[munkeyh]

Hiya, and thanks guys.

I did disconnect the vacuum pipes and blocked them whilst I set the timing - wasn't sure if that was totally correct? I've seen differing opinions? I'll recheck the timing again.

I've not had several hours of running out of mine yet, I didn't want to keep running it as I was worried about damaging something considering I don't know whats wrong. I've only done a couple of very short runs. I know it needs running in so I'm not racing it but I don't think I have full power. If I blip the throttle REALLY quick from the engine bay it hesitates too.

I'll check the timing again and see if I can tell if its advancing.

Thanks for the offer of using the exhaust analyser, thinking about it I guess I could take a short run to the local garage to get them to check the fuelling. I didn't want to trust them with anything else. I wanted to learn how to do all this myself.

Cheers
Mark

[123-jn]

ASfter I rebuilt mine the initial compressions were low but after 2000 miles we are up to 185-190PSI HOT, initially 150-175. 15-20 PSI between cylinders is ok but 5-15 would be nicer.

[phild]

Not sure if it will help but my 2.1 injection has been running rough for years especially when I back off the gas pedal going down hill. Just discovered a small crack in the rubber intake boot from the air cleaner box. I used some silicon to seal it and it's like a new van.

[slowcoach]

Air leaks in the intake, caused some roughness on mine. I had tape around the join between throttle body and air box for years (where there's quite a bit of flex and a jubilee type clip), which sorted it right out. Looked kool too

[munkeyh]

Cheers folks, appreciate all the advice. I'll start the hunt for air leaks although it might have to wait for the weekend again.

Interestingly I drove it around it around the block last night and when I pulled back up and left it at idle my fuel pressure was around 1.8psi (which has gone down from where it previously was at well above 2psi?). Disconnected the vacuum from the fuel regulator (that's what the manual said to do) and it made no difference to the fuel pressure.

I've put a video here on youtube, you can hear what its doing rather than me trying to describe it.

https://youtu.be/JldZid20VWA" onclick="window.open(this.href);return false;

Cheers
Mark

[itchyfeet]

I hope you mean bar not psi 2 psi is nothing

Bentley says 2 bar idle vac connected or 2.5 bar with it disconnected.

[munkeyh]

Ha ha, yes I meant bar not psi - oops