96 wizard woes

by **stardog** » Sun Jun 21, 2015 6:19 am

Need advice on 96 wizard 4jg2t I found the injectors where not lined up with the position marks on the block where the glow plugs are. They where miles out that would explain the white smoke tons of it on start up.
So I adjusted them to where they should be now I have tons of black smoke even at idle could the fuel delivery be turned up to much should I back it off and adjust the idle adjuster bolt on the accelerator cable to get it to idle properly I remember muvit telling me the mechanics in Darwin had to turn the fuel delivery up to get it to idle it kept stalling or something like that.
Plus it has a inlet manifold off a 2.8 engine no boost pressure valve on it could this affect the running of this engine it seems to have a heap of blow by back through the air inlet pipe into the turbo.
I didn't get a chance to check the timing yet as well.
Stardog

by **geeves** » Sun Jun 21, 2015 7:20 am

if the injectors are not alligned the fuel does not atomise properly as it hits the side of the precombustion chamber. I have been told this can lead to cracked heads. If you are sure yoiu have alligned them correctly then along with the info from Muvit about the previous history of that engine it does sound like reducing the fuel might work. I suspect other issues though. Also check valve and injector timiming. The inlet manifolds are as good as identical
From memory Muvit had a bad run with that engine starting with it expiring a long way from home and having to use a garage no one knew.

by **stardog** » Sun Jun 21, 2015 7:32 am

Ben spent a lot of money on it and its in real good condition as well it was to good to get scrapped that's why I bought it off him.
The only problem is with the engine I also found the air filter installed upside down in the air box I got the injectors as close as I think they should be.
The pump and injectors have all been done up not long ago as well.
If I cant sort this engine out myself I will take to a diesel specialist in Sydney.
stardog

by **geeves** » Sun Jun 21, 2015 9:46 am

Sometimes have to wonder about the policy of no name and shame garages that do bad work but the libel risk is just too high and we have no money to fight court cases

by **stardog** » Sun Jun 21, 2015 10:28 am

That's the only problem living up in the top end limited diesel mechanics I don't know if the guys who done the sleeve on the engine tried to time and tune it as well.
if it stops raining I will have a look at the timing today.
The mark on the crank should be at 12 oclock no 1 piston tdc and the 2 8mm holes should line up on the cam and ip going by the book.
I cant remember now if turning the pump in retards or advances timing on a belt drive engine.

by **stardog** » Sun Jun 21, 2015 1:56 pm

Turned the fuel down 1/2 turn didn't smoke so much but ran rough as guts until it warmed up after a minute or 2 I also found on the thermostat housing the sensor with 2 wires on it on the top near engine rocker cover the wires are snapped off at the base could this be the one to the csd on the injector pump that advances and retards the timing.
Also got a knock in the engine as well now so it could be the timing as well.
Can you remove the csd of the injector pump will it make any difference I've ordered a new sensor im starting to think this engine has a curse on it black magic.

by **stardog** » Sun Jun 21, 2015 7:49 pm

geeves you wouldn't by any chance have a photo of your 96 wizard thermostat housing with all the sensors just wondering if they are the same wiring as mine.
Cheers stardog

by **geeves** » Mon Jun 22, 2015 3:30 pm

sorry its nearly snowing outside right now

by **stardog** » Mon Jun 22, 2015 3:44 pm

Pretty cold over here to I found some photos of the sensors on the net. I found I hadn't set the injectors in the right place so this weekend I will remove the inlet manifold and do it right and swap the old injectors to new ones I have spare.
Also I will check the timing as well I have feeling it is out a tooth.

by **stardog** » Fri Jun 26, 2015 6:50 pm

Finally got a chance to line up the injectors today with the glow plugs and check the timing everything lined up in the timing marks.
Bad part - 1 harmonica balancer bolt broke doing them up I didn't use much force on the socket dam and double dam to put it politely *^%#!&^ are other words used.
I also found that the return pipe for oil from the turbo leaking that's why the turbo was noisy whistling so I will look at that tomorrow just the gasket I hope might even take the turbo off it and use one of my spare ones I have to eliminate if the turbo seals gone and reason for blowing smoke.
But I will get it back together tomorrow and see if it still smokes the other thing I found I pulled out no 2 injector and it was soaked with diesel could this be a dodgy injector.
I'm about to put some more Band-Aids on my fingers and some more pain away on my back and a few beers and hope I can walk in the morning.

by **stardog** » Sat Jun 27, 2015 5:16 pm

Happy days after 2 days under the bonnet I think I may of fixed it heap of smoke on start up then its gone after it warmed up turned the fuel delivery out 1/2 a turn more but im still need to play with it a bit more.
The turbo return noil pipe had no gasket where it connects to the turbo so I made 1 up no more oil leak only thing now is replace a top heater hose is split losing coolant.
Just got to sort out climate control no fan or lights working I think it might be a vacuum pipe problem .
Also no light comes on when you put it in 4wd hi or low I wouldn't mind getting rid of the soft system and just put the same as my MU set up with free wheeling hubs on it.

by **geeves** » Sun Jun 28, 2015 5:03 pm

Nothing wrong with the SOTF system except it does use a little more fuel.
The vacuum pipes are set up funny though which I cant get head round. If the clutch is spring loaded then it is understandable. Soon after I bought the wizard I had a grinding noise coming from the clutch. It was jumping half engaged.
I had a good play with mine when it was playing up and rewired the solenoids to operate manually via a switch. One in one out. Was meant to be for diagnostic reasons but then thought about how nice it is being able to maneuver a trailer in low range 2wd

by **stardog** » Sun Jun 28, 2015 6:16 pm

4x4 is not engaging tried it today on a sandy hill at my place only rear diff working don't they have a air vaccum tank on the chassis I cant find it also im getting a brown charge relay from NZ shipped over as well might fix a few other problems with the climate control.
Going to get manual hubs as well never been a fan of auto hubs I have got the engine running fairly ok but today still blew a heap of smoke on start up but is idling a lot better I suspect a faulty injector im going to bite the bullet and book it into a diesel place this week I have new injectors and a pump spare I will take them over as well I have done the best I can with it and fingers with Band-Aids all over them and new Isuzu curse words.

by **geeves** » Mon Jun 29, 2015 5:25 pm

sotf.jpg

the vac tank is on the outside of the chassis roughly directly below the front passenger door handle.

by **stardog** » Mon Jun 29, 2015 5:43 pm

Thanks Geeves I was looking under the bonnet for it I will have a look tomorrow before work im back on dayshift for 2 weeks.
I have sent emails to a couple of places in NZ trying to get hold of a brown charge relay no replies yet see if I get any back I just cant get 1 anywhere over here in Australia.

by **stardog** » Tue Jun 30, 2015 9:17 am

I found the air tank it under the front passenger door at the front I will follow the vacuum pipes and try and find the problem.
I have 2 new brown charge relays coming from NZ on the way from Canterbury very helpful people.

by **Hamdog** » Tue Jun 30, 2015 11:47 am

stardog wrote:I found the air tank it under the front passenger door at the front I will follow the vacuum pipes and try and find the problem.
I have 2 new brown charge relays coming from NZ on the way from Canterbury very helpful people.

ahhhh i was wondering what that tank is on mine , now i know !, also where did you get the relays from? i need to buy one

by **geeves** » Tue Jun 30, 2015 3:31 pm

I have seen them for sale on trademe. Look at isuzu alternator listings

by **stardog** » Tue Jun 30, 2015 6:41 pm

I always look on trade me as well only seen the blue ones also tried eBay but not much luck.
I got 2 brown ones from the south island [ Canterbury auto electrics 159 waterloo road Hornby Christchurch 8042 phone 033669600 ] the guys name was Troy very helpful just tell him Steve from Sydney Australia put you on to them.
I forgot to mention im a member of club Isuzu to him I was so stoked finding some new brown relays.
part number is jidco 8970634412 hope this helps out people in the club.

by **stardog** » Fri Jul 03, 2015 4:45 pm

After talking to Ben finally sorted the climate control out all good loose wires and relay.
going to change the glow plugs tomorrow see if it starts better changed the glow plug relays and the glow plug timer already.
I've still got some grey smoke at idle when warmed up could be a bad injector I think don't really want to be changing them with out the gaskets and seals to put the new ones in.
And change the fuel filter first see if that helps.

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