Yanmar 1GM injection pump clicking when engine is turned

timb106106

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8 Jun 2012
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My 1GM ticks three times in quick succession from the area of the injection pump fuel rack when I turn the engine over. Does yours? Is it supposed to? If I turn it by hand I can tell the three clicks are towards the end of the compression stroke and reoccur when I turn the engine backwards and then forwards again. With the oil filler cap removed I can see that when the engine is turned to where the clicks occur the engine stop lever is prevented from working ie the fuel rack does not get pushed backwards at that point.
The engine runs fine BTW I am asking this to try and prevent (further) damage.
This started to occur when I removed the injector and injection pump for professional inspection and overhaul. The injector was rebuilt but the pump was not overhauled. I replaced it without dismantling or adding any shims.
I did however make a mistake when I reinstalled it and initially did not engage the fork of Governor Lever 2 in the fuel rack and the engine ran away when initially restarted. I lifted up the pump again and engaged the rack without further problems. The engine starts, runs and stops fine. It returns to idle smoothly. Have I missed something else when reinstalling the pump? Is it internal to the pump or one of the governor levers? Is it perhaps the Governor weights on the gear? It sounds like something on the gear and you can feel the high pressure fuel line which rises vertically from the pump vibrate slightly when the ticks occur.

It occurs when the starter motor, alternator and the gearbox is removed BTW in case anyone is pointing a finger in any of those directions.

Have a play with yours, get back to me.
Thanks
Tim
 
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