'91 Ford F800 - Diesel Forum - TheDieselStop.com
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post #1 of 5 (permalink) Old 01-21-2018, 03:52 PM Thread Starter
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'91 Ford F800

Have '91 Ford F800 that just replaced injector pump. After putting pump on won't start other that off ether. Will run just fine after but blows enough white smoke to clear a neighborhood. What could be causing this. Is it due to bad pump rebuild or possible injector failure after rebuild.

Last edited by Dick Cutting; 01-21-2018 at 04:53 PM. Reason: relocated the ' item which was originally posted after the year number 91 '
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post #2 of 5 (permalink) Old 01-29-2018, 09:17 AM
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What engine do you have, if I remember right a lot of F800s back then had 3208 Cat diesels?

Heavy truck and diesel mechanic (thankfully retired after 30+ yrs)
'91 F-250 SC 4X4, 5spd. ATS Turbo, 3:55 diff.
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post #3 of 5 (permalink) Old 01-29-2018, 11:43 AM
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A 1991 Ford F800 diesel would have either a 6.6L or a 7.8L Ford New Holland engine.

Did you purge the air from the injection system by cracking open the injector lines at the injectors then cranking the engine with the ignition in run? Did you get fuel spitting out of the fittings?

If the engine did not smoke before replacing the pump I suggest that you recheck the injection pump timing first.


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Last edited by ford_doctor; 01-29-2018 at 11:46 AM.
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post #4 of 5 (permalink) Old 02-02-2018, 05:03 PM Thread Starter
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Not sure were I got my timing off or what. I brought piston up to tdc with screwdriver right were intake valve starts to open. Harmonic balancer shows to be correct also. Retarded it 10 degrees like the valve cover calls out and no fire still. Not sure if my strokes are off or what. I am new to diesel motors so looking for any ideas. Thanks
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post #5 of 5 (permalink) Old 02-03-2018, 07:22 AM
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Injection begins just before TDC so if cylinder #1 intake valve is opening something is wrong. I don't see how the engine timing would be off unless you had the engine apart or the gears off the front of the engine. The pump timing does not rely on timing marks or any marks on the crank damper... so I don't know what you are doing or looking at there.

BEFORE you can install the pump you must time the pump drive gear to the pump. There is a special tool, Injection Pump Aligning Pin T91T-9000-A that aligns the gear with the hub on the injection pump and the engine crankshaft must be in the proper position by using another timing pin that locks the damper. For that you need Damper Aligning Pin T87T-6379-A through hole in timing bracket on engine front cover until timing pin goes all the way into the correct slot on crankshaft damper. Once the crank and the pump are set up properly THEN you install the pump.

If you do not use the tools you will never properly time the pump. This is critical because diesel fuel burns slow in comparison to gasoline therefore the window of time where combustion takes place is narrow and quite specific especially with the older engines with mechanical fuel pumps. Even if you guess and get the engine to start, engine performance and emissions will be adversely affected.

Good luck!


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Last edited by ford_doctor; 02-03-2018 at 07:25 AM.
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