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#1
06-02-2011, 12:24 AM
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Sounds like you're working on the IP timing side of things. The noisy running could certainly have been because of the cold start device being stuck.
Did a new fuel filter make any difference? Checking cam timing requires having the special cam locking plate (similar to VW tool, I will look up the Volvo number next time I have my books out), and you have to remove the valve cover and rear timing belt and reset injection pump timing when you reinstall the rear belt afterwards. A bit of a tricky procedure but if it's not right it will make it run poorly... should have been set correctly at timing belt replacement though, assuming the garage that did the job had the right tools and knowledge of how to do it properly on this exact engine. If they did, then no need to check it, but if there is any doubt, then it should be checked by someone with correct equipment and know-how -- and the crankshaft balancer bolt torque should be checked too, since that also requires special tools and needs a massive amount of torque. If it wasn't torqued properly and it comes loose then you can end up with major engine problems In my '86 740 TD wagon, with a heavy foot and ZF automatic in mostly city driving, I average around 26 mpg (US gallons). Don't know how that compares with the Imperial conversion. 26 US MPG is not bad for a big, comfortable, safe station wagon that can haul lots and is a pleasure to drive.
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86 745 D24T/ZF 345k lifted 2.5" 83 764 D24T/M46 155k 
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#2
06-02-2011, 05:39 AM
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Changing the fuel filter didn't really make much difference to be honest. The old one looked fairly clean inside it.
I can get a set of the Monark 273 nozzles for £74 inc p&p, and a local diesel specialist says they will fit the nozzles at 2400psi for around £40. As I said in my other post it almost sounds like I've got 1 injector knocking/"clacking" at 1500-2000rpm. And is even more noticeable on the tank of biodiesel it has at the moment. I think since disconnecting the cold start it has quietened down a little, but the knocking/"clacking" is still there. Only stops on over-run - i.e. when deccelerating when holding it in a lower gear (2nd for e.g.) it goes perfectly quiet when it falls from 2500 until it gets down to about 1500 and starts clacking again then. I think 26 mpg US will be around 30 mpg UK, so about the same. Although I'm now getting about 28 since I turned the diesel screw up a bit - but at least it accelerates a bit now! Worthwhile getting the new injectors for around £100? Is there anything else that needs replacing apart from the nozzles?
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#3
06-04-2011, 02:34 PM
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Hi Ian 2000T
Not sure if you have fixed your Engine, but a couple of other things can cause a clacking sound as you describe. The vacuum pump can make this noise and also one or more worn out Hydraulic valve lifters,if you do not have these then also a noisy tappet could be the problem.
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