do you have egt and boost gauge ? from what you said the timing is right but as i am sure you know the pump rotates on it's mounting bolts , towards the head more timing away less

 

Indeed it does, but the injection pump on a 4BD1T is on the other side of the block to a 4BT. On the Isuzu top of the pump away from the head advances timing. Same direction (clockwise from drivers perspective).

 

sorry didn't see the 4BD1T over looked that :emb: never had much to do with the isuzu stuff

 

What color smoke?

I would suspect the outer ring of the balancer has slipped if it seems that far off and starts at all.

 

Smoke is dark, black to dark gray. It is almost not existent until full throttle. Then it is only faint.

 

If your EGT gauge max's at 900F, then it's not much use. Shift it to the exhaust manifold and make sure the probe hits the middle of the gas stream.

 

I may have not been clear. The EGTs max out at 900f not the guage. The gauge has a range of 0 to 2000

 

General rule of thumb (remembering tha all generalities are false) is that the temps after the turbo are roughly 300* F cooler, so 1200 with a little smoke isn't bad.

Not great, but not bad.

There is a practice some people use to drill the exhaust manifold without disassembly, drill it to final (tap) size in one step, with the engine running.

Don't let it warm up first, the exhaust should blow the chips fom the drill back out as it breaks through.

Shut the engine down, grease up your tap (to stick most of the chips to the tap) backing the tap out frequently to remove the chips that are stuck to it (regrease before tapping further) when you are done with the tap, restart the engine and it should blow most of what's left of any chips out the hole you just tapped.

Haven't tried that method myself, but it one's highly recommended by several of the members here.

Best of luck.

 

General rule of thumb (remembering tha all generalities are false) is that the temps after the turbo are roughly 300* F cooler, so 1200 with a little smoke isn't bad.

Yeah, of all rules-of-thumb, I like that one the least. The temp drop across the turbine depends on the pressure ratio across it, the absolute temperature into it and the efficiency at that flow.
You can get as high as 300C across a turbine when it's working hard. So I tell everyone to shift the probe instead. Knowing beats guessing every-time.

 

I didn't put the thermocouple in the in the manifold because I was concerned about drilling into cast. Has that presented any problems for anyone?

 

No problems, cast drills and taps beautifully.