Recommendation needed: Injection Pump Rebuild

[CapnSass]

Originally Posted by ngoma

Hold on! I like hugs too but if you would answer his question:

Then we would have a MUCH better idea of what to suggest to you to make this a less painful situation and arrive at a solid solution.

We WANT to help you.

We CAN help you.

We WILL help you, if:::::::::::::::::::::::: you play along with the 20 questions game. There is a certain "best" method to installing the injection pump and timing it. ANYTHING ELSE will end up with big problems (as you are seeing now) and is the cause for premature deaths of many of these cars. It is not so complicated but it is "out of the ordinary" for most mechanics and many think they can get the job done using methods that have worked for years on other cars. But, here even good intentions can cause bad results.

This engine will not run well if it is not timed correctly. To time it correctly requires the proper (specialty) tools, and following the correct method in the correct order. NO CHEATING! Unless you are lucky.

So let's approach this like a science problem, take a step at a time, observe, note the results, and report back.

Again,

Please answer and watch how we start making progress!

We were using an aftermarket manual... I think. The book is out at the shop. I know it's not a green book but don't remember exactly what. Maybe just a chiltons or something. This is all a very big learning experience. I've got the timing dial tool on the way. I've been told the diesel mechanic's methods are pretty solid but as you've mentioned above, I am not confident he used the proper methods or just methods that have worked on various diesel engines.

We did try switching the 'in' and 'out' banjo bolts as suggested by v8volvo which didn't change the results. Also installed a new fuel filter and double checked the line contained no air bubbles.

also wanted to apologize for being intermittent with my responses. The vehicle is about a 15minute drive from my computer. I have my phone but web coverage is spotty and typing away on that little screen is challenging. I am naturally long winded (barely ever have a short answer (I'm Irish, lol)) so you'll be able to tell the difference between my phone replies and computer replies. Either way, I am grateful for all the info and tips shared while getting my volvo up and running.