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4010 diesel mule possible bad injector pump?


markymopar
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Hi I'm new to your site. I work for a place that has 5 diesel Kawasaki mules. We have had great luck with them until one of our crew members tipped over a 2012 mule one day. Ever since then it has been blowing unburned diesel smoke out the exhaust and fuming up the shop. It starts up and hits on all 3 cylinders for about 10 seconds then starts missing on the number one cylinder. I have replaced all 3 injectors and have replaced fuel filter and put injector cleaner through it. It has a lot less power than the others and finally will clear up and quit smoking for the most part when fully warmed up.. It also will hit on all 3 cylinders when warmed up.. I was wondering if anyone else has had a similar issue and if there is a good easy cheap way to test this.. My only other thought is it has very low compression now in # 1 cylinder now. Any help will be appreciated.. Thanks

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ok well I checked the fuel pressure and it was squirting out well with great pressure.. I was going to do a compression test and did not have an adapter big enough for the hole to thread in. So I ended up pulling the head off and on that same cylinder.. the exhaust valve had all sorts of burnt oil caked to it on the face and on the back side. I pulled the valve and wire brushed it. There were no burnt or bent valves. The pistons also had all that oil caked to them as a result from laying on its side.. I will find out tomorrow if this cures it when I get the new head gasket.

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So I got it all back together and still the same thing. I put a new injector in that cylinder as well. When running if i loosen the injector line to that cylinder it goes to running better and not missing on that cylinder anymore.. Im leaning towards it being something wrong with the injector pump again

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  • 6 months later...

Hi markymopar,

I am glad to have found this topic, though sorry for your problem... I've got an issue exactly like yours - same model and year vehicle with low mileage/hours that was running perfectly, got completely tipped on the left side, as result combustion chamber(s) in the engine got flooded with engine oil. Cleared them by removing plugs and turning the engine, but now it seems to be running on two cylinders only.

Wonder, if you had your issue resolved, would appreciate any info, thank you.

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Hey I seemed to have gotten the issue resolved. It has been good for about 6 months now. I ended up pulling the complete motor out of it and pulled the oil pan off and found that one of the cylinders had a bent connecting
rod.. I pulled the head off and pulled the rod and piston out and bought a new one for a 100 bucks and reused my bearings and put it back together with a new head gasket and it runs great. The reasoning behind it was when
it got tipped over the oil got on top of the pistons. By trying to start it it bent the connecting rod so the piston was no longer able to cone to the top of the cylinder. It was not able to build enough compression to fire the cylinder and was dumping raw diesel out the exhaust. Hope you can get yours figured out. thanks and good luck

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  • 4 weeks later...

Markymopar, thank you so much for the info! I'm glad you got that problem solved.

What I found so far in my case is probably the same issue - I removed the cylinder head and found that third piston comes up 3mm short of the block top - that, for sure, indicates bent rod, so I am going to pull the engine, too.

Wonder if you can find time to help me with couple questions: for one thing, you said you reused bearings - did you evaluate them somehow, or just put them back together? I am asking because when I turn crankshaft, I feel something is snagging there even if slightly, that could be bearings on a bent rod... wonder if you remember something like that in your case.

Also, service manual requires special alignment jig for aligning engine with transmission, when instaling it back - did you use that tool, or somehow worked around it?

Guess, that engine is not too heavy for two people to pull out and put in :).

Thanks for your help,

Vlad.

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