1HDT Recent Behavioral Change

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May 23, 2019
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WNY For Now
I have a weird one for you guys.

I built my rig about 3 years ago (see build thread linked below if you want an overload of crap info on that). It is a 1995 FZJ80 that I converted to a 1HDT/H151 with GTurbo, intercooler, bigger airbox, rebuilt fuel pump, rebuilt injectors, 3" exhaust, etc etc. I'm only pushing about 19psi because I wanted it to be reliable, not a torque monster. I've driven it about ~35k miles in the last couple of years and it's been amazing. One year ago I ran compression numbers and all 6cyl were very good with very little deviation between them.

Over the last 4-5mo and 8-10k miles it very slowly started running worse. At first I didn't notice. Just a dim sense that it was louder and rougher. Several months ago I noticed that the shift lever would vibrate violently on downshift engine braking, which it hadn't done before, and I chalked that up to it maybe needing engine mounts (even though those were only 3yrs old). Eventually it slowly got to a point last month where I was getting concerned. It was idling rough, almost a miss but not quite. It was smoking more. Idle speed was down about 50rpm. It was louder/rattled more than ever. I could feel the increased engine vibration in my butt and in the steering wheel driving it down the road. I was worried that it was time for a rebuild.

A few notes:
-I travel a LOT so I rarely hit the same gas station twice. So I don't think bad fuel is to blame.
-I keep up on maintenance, replacing the air filter frequently, as I run a lot of dusty roads. Fuel filter replaced yearly (although I only run the stock filter set up).
-I have had a light oil leak at the turbo outflow for a while now that I need to figure out.
-One of the last things I checked was to open the petcock on the fuel filter. No water came out but I did get a puff of air. However I was at 7000ft when I did this.

I was headed back to home base (although over 2000mi to get there) a couple of weeks ago and PLANNED to buy some Diesel 911 and top the oil off with some Lucas additive to see if either of those quieted it down because my inspections found nothing wrong anywhere else under the hood.

The day BEFORE I made it to a town to get these supplies and after a rough 30-40mi washboard run, I fueled up and noticed when I pulled away that the truck seemed to be running smoother. I was flabbergasted. Some more driving and it was obvious that the old 1HDT was running like a freshly oiled sewing machine. Maybe better than ever before. And shockingly, engine braking now barely wiggles the gear lever. 4 tanks of fuel later and my MPGs are up ~15% (3-4mpg).

What the bloody hell happened? God definitely doesn't like me enough to have intervened in this.

All I can think is that I had an injector that was sticking? Or maybe a valve had some schmutz stuck in it that kept it from closing 100% causing a slight compression leak?

But the real head-scratcher for me is the reduced vibration under engine braking. What could cause increased vibration under engine breaking? Or alleviate it? I think the biggest clue is in that. Is that indicative of one cylinder having lower compression? Or a lack/excess of fuel?

Any ideas?

I love that it's running better but I hate that I don't know WHY. Hahaha. Partially because it could turn back in the other direction at any time. And I need reliability!
 
Perhaps some fuel starvation was occurring. The in tank fuel pick up screen may have been dirty or plugged up.
If the truck runs better all of a sudden, I doubt you had any issues internally to begin with.
 
Is air build-up in the fuel filter a common problem on these engines?

Fuel starvation is a possibility. Odd that MPGs went UP after though...

All my fuel lines were brand new when I did the conversion. Sender/in tank filter was new as well. Tanks was freshly lined for the conversion to diesel.
 
Usually any air in the system will cause white smoke or erratic running of the motor.
I have not heard of air trapping occurring in the filter as a common issue.
Best way to monitor for any air is to attach a clear diesel fuel line between the IP and the fuel filter housing - then patiently watch for bubbles.

That's odd! would be still worth taking a look into the tank. Wonder if you got some contaminated fuel with microbes that grew into biomass?
 
Filter housing was not new. I believe it is NLA or I would have replaced it.

I have checked for leak-down by pumping the primer after it sits and it's never needed more than a 1 or 2 pumps before its full pressure. I assume that's pretty normal.

It has never had any hard start issues. Barely have to touch the key.

Kroll: I may run a diesel treatment/anti-microbe through just to be sure. But very odd it just went away on it's own very suddenly. The smoke was definitely darker and smelled oily as opposed to raw fuel.
 
Sounds like the filter housing is still good. You could always buy a filter housing from a 70 series or 100 series to replace the NLA one.

If I were you, I would consider running a diesel additive at all times.
Yeah, really odd it went away on its own.
 

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