Sorry for a long post.
I would appreciate seniors like @Xulfiqar bhai or others to help me with my situation.
I have a 1C in my Toyota carina 1975. i recently got it overhauled. There was some slight crack in head so it had to be replaced. As per mechanics & kharad wala guy's suggestion bought 2D's head. Plus crank also was replaced. Engine got assembled all was well. Only thing remaining was nozzles and diesel pump service (it was slightly leaking as well). It was suggested to complete 1000km running first and then visit diesel lab. At this stage engine sounded loud and minor bluish white smoke, to which it was said pump overhaul will smooth it all. Acceleration will get better as well. And smoke will vanish as well.
Completed running, had to visit lhr frm isb. So after some good 1800km I took the pump and nozzle to diesel lab as referred by mechanic. After inspecting on his machine He said k pump kamzoor hai and nozzle bhi replace hungi khatam ho chuki hain. we asked him to do all the required stuff. He repaired the router, changed the nozzle (650 number, previous was 628/638 I guess, donât remember exactly but it wasnât readily available, 650 was) in short did all the things to say k pump ub A1 ho gaya hai.
Mechanic installed the pump and car started fine but with lots of white smoke. pump guy came and did minor adjustment and said to visit him next day for setting.
I visited him the after two day. During these two day there was missing and lots of white smoke in morning. Diesel lab guy tuned the car. Car now had a very good acceleration, sounded smooth as well. But there was slight vibration in second and third gear. So I visited him again after some hour. After some adjustment vibration was reduced more but did not go away completely.
Next morning I faced the same issue, missing and lot of white smoke. In addition to smoke and missing vibration was back. Went back to him and this time his partner tuned and said karak khud thori ziada ki hai. Kuch time main set ho jai gi. Aur jaise ap ne engine ki running ki hai waise pump ki bhi karain some 2000km, iski sound achi ho jai gi.
But next morning same issue with missing and smoke.
Another visit, pump was taken again to deisel lab, and they did their satisfaction again and sent it back. And again next morning we faced the same issues.
This time mechanic first sent us to kharad wala who did some tappet adjustmentI(I was not there so canât explain exactly). And said ek do din check karain.
Next morning we faced the same issue again. Missing and white smoke.
kharad guy also mentioned us that there is some space in your valve guide or something, so karak(kir kir sound that comes as soon we put our foot on accelerator) wonât go away forever. It will get adjusted but will come back eventually. So only solution is to change the head. (we had bought the head separately, all set ready to be installed. This kharad guy dint do any work on it during engine overhaul. He only worked on block and crank). Next day after tappet adjustment missing and smoke was still there. Meanwhile we talked to the guy we bought head from, and he suggested to press the lifty pump ( the push button that is on diesel filter) before starting.
we did as he said and the smoke and missing went away. Next couple of days car started smooth without lifty pump press;
so after three successful days we went to the pump guy to do his necessary tuning which was supposed to be done after second time pump was calibrated.
Now only work was acceleration(car was feeling heavy to drive) adjustment and that a karak.
He did his adjustment and said pump ki karak khatam kerdi hai but yeh kir kir total khatam nai hogi head ka masla hai main full adjusment ker chuka hun. This time I was not satisfied with car acceleration. Wo baat nai thi jo first time adjustment k bad acceleration ki thi. But guzara tha.
Next morning missing and smoke was back. Even not accelerating as it did on tunning day. Dint went back to the pump but told my mechanic about the current situation.
That Kir Kir was there from the start, Itâs not the karak. It comes the moment I put my foot on accelerator and increases as I accelerate. Initially I was told pump k kaam k bad sab awazain khatam ho jai gi.
Summary
After engine overhaul:
all was good except:
-sound was loud (Karak)
-acceleration and overall speed was less.(dint push beyond 70-75km (5th gear) on motorway bohat loud ho jati thi)
-leaking pump
-slight white smoke (not on starting, just general smoke)
-that kir kir sound that comes as soon as I put my foot on accelerator and increases as rpm goes up.
After multiple pump service and adjustments, current situation:
-there is a difference in overall sound but karak seems to be still there and kir kir sound on acceleration. So many kir kir karak sound now. Idle engine sound without accelerator push is better, no karak in it.
-leaking pump solved.
- missing and white smoke in morning. And if car been not used for 4 5 hour during the day same missing and smoke upon starting but considerably low than morning. ( lifty pump as also been changed)
-virbration in 2nd and 3rd gear (this was not there before pump overhaul. there wasnât slightest hint of vibration at any speed before.
-not satisfied with its overall speed and acceleration. Tunning day pe acceleration theek hoti hai, but kuch din bad wo baat nai rehti.
Last time pump overall was done in 2010. Nozzle service and 2 nozzle replacement was done in 2013, after this nozzle service car sounded as smooth as a petrol car. In all these years I never faced missing in morning and this much white smoke. Just a general one that is there at cold start.