4jg2 no power and knocking

[Sylvester]

Hi guys great website , ive just finished painting my 93 swb bighorn 3.1 4jg2 , it came up real nice however it sat around for a long time and on my way home from the painters I suddenly lost all power and the engine was knocking if I went over 2000 revs , there was a loud whirling noise coming from the exhaust , oil and water is fine and it never got hot , so i drove it home in first gear just touching the acc , lots of black smoke coming out , got home ok it was only 5 k away , checked oil and water all fine no lights coming up or anything , still starts up and idles fine ,

so i removed the pipe going to the waste gate acuator and tried to move the waste gate manually It was rock solid i started at 15 psi then moved to 30 psi still no movement at all , so now im in the process of removing the turbo completely to check it out for sure ,

Im also gunna chuck in a blank for the egr from the valves to the intake and just leave all the pipes there , is this fine ?

is there anything else anyone can think of that I can check ?

tried to post a photo but kept saying my image was invalid im using jpeg ?

thanks in advance .

[geeves]

jpegs are ok but make the size 640 x 480 or they are too big.
Turbo sounds the right place to look. To check without removing take the inlet pipe off and check for play A tiny bit of front back play is acceptable although not ideal but any side movement is bad. Also try and spin with your finger. It should turn 3 or 4 times from a finger spin.
Other options is timing slipped injector or pump failure etc

[Sylvester]

Ok so it's been hard to find time to work on it lately but ive managed to get the turbo off relatively ok , bit of a struggle with no 12mm rachet spanner , when I looked at it the waste gate was stuck closed , I gave it some rost off and a wiggle and now opens easily with a bit of compressed air , there's no play back and forth and a tiny amount up and down , no scratches by the compressor wheel but will take it to my mate to check out anyway . I've blocked off the egr . now will remove the timing cover and check timing , may replace belt anyway and all hoses while its stripped down somewat ,
is there anything i'm missing ?
should i just put everything back together after I've done the timing and see what happens ?
, or is there something else i should check ?

[Sylvester]

IMG_20160226_163841.jpg

[Sylvester]

ok time for an update I have just finished , this is how long it's taken me only getting a few hours a week to work on it outside ,
I pulled the turbo , injectors and glow plugs out got new plugs , injectors reconditioned and looked at the turbo , seemed fine with little play only stuck waste gate , so threw everything back together with new hoses all round new washers etc , blocked off egr , installed catch can , advanced timing to 0.7 , then started it up seemed fine at idle but would not go past 2000 rpm and still had whirring noise from back which I originally thought was turbo,
but turns out when I went over the railway tracks on the way home it must have knocked all the rust out of the muffler and blocked it , so I cut off exhaust just after the qws valve which was working ok, and now she's got tonnes of grunt with zero smoke and I haven't turned up the gas yet which will be next after I fit new exhaust , and fix new indicator problem ive developed , thanks for the help it went real smoothly no bare knuckles or rounded bolts
cheers im off to the electrical forum now .

[turnturn]

If you are doing work on your exhaust...get rid of the QWS while you are there.

[Sylvester]

Yes I will be replacing the lot with 2.5 inch and a flowmaster or the cheap version of flowmaster , only thing im not to sure about is the flange that attaches to the turbo ,
should I just cut that off and weld the 2.5 inch to that or weld it a couple of inches down or remake a new one , I will be doing the lot myself as I have access to a bender and will get some welding practice out of it as well , hopefully I won't get to many holes , what have others done in the past ?