Oil leaking from injector housing.. bad news??

[LeftFoot]

300tdi
Engine reading 90,000 miles

Issue: Oil running from injector #2 housing despite two attempts at sealing it using brand new copper washers.

When injector #2 is removed the body is covered in oil whereas the other 3 injectors are only coated with fuel when removed.

The images attached compares injector #1's housing to injector #2's after a short drive. The oil is running out at such a high rate it quickly finds its way down to my driveway which is quickly becoming a mess.

Is this bad news? I have a theory what it is but I would like to hear your opinions please..

 

[Kwakerman]

I'd look at the rocker cover seal first (just replace it). Fairly cheap and simple job, also check that the breather pipe isn't split. Give it a good clean up and then watch, If that doesn't cure it then you may have a crack in the head or pourous aluminium but that does seem quite a lot of oil for the latter.

 

[LeftFoot]

Rocker cover seal replaced the same time as injector seals. Area was cleaned and all hoses in good condition. Can this oil not be blowing past the seal? Remember when the injector was removed it was coated in oil.

 

[Turboman]

300tdi
Engine reading 90,000 miles

Issue: Oil running from injector #2 housing despite two attempts at sealing it using brand new copper washers.

When injector #2 is removed the body is covered in oil whereas the other 3 injectors are only coated with fuel when removed.

The images attached compares injector #1's housing to injector #2's after a short drive. The oil is running out at such a high rate it quickly finds its way down to my driveway which is quickly becoming a mess.

Is this bad news? I have a theory what it is but I would like to hear your opinions please..

Are you sure it isn't a diesel leak that is washing engine oil down the engine?

 

[Kwakerman]

Rocker cover seal replaced the same time as injector seals. Area was cleaned and all hoses in good condition. Can this oil not be blowing past the seal? Remember when the injector was removed it was coated in oil.

There shouldn't be any oil on the other side of the seal as it is hopefully fuel that the injector is trying to squirt into the combustion chamber

 

[Kwakerman]

Thinking about it, is the engine actually running ok, I suppose there is the possibility that oil is draining into the combustion chamber when stopped and this oil is being forced out when you try starting (basically a miniature version of a hydraulic lock but without the bent con-rod). If that were to be the case I would expect to see a lot of blue smoke on start

 

[Scooby22]

Did you use genuine copper washers on your injectors, see this video.

 

[LeftFoot]

Thinking about it, is the engine actually running ok, I suppose there is the possibility that oil is draining into the combustion chamber when stopped and this oil is being forced out when you try starting (basically a miniature version of a hydraulic lock but without the bent con-rod). If that were to be the case I would expect to see a lot of blue smoke on start

Two things I have noticed recently:
1. Starting on mornings (cold start) usually takes 2 attempts at swinging. Fires up on the second attempt each and every time. Compression issue?

2. I am seeing a little blueish smoke from exhaust at idle. (Not only at startup. All the time. It is barely visible).

Would not oil on injector #2 indicate that it is getting past the piston rings?

 

[LeftFoot]

Did you use genuine copper washers on your injectors, see this video.

Yes sir I did. Genuine, and installed the right way round also. Even cleaned out housing first.

 

[LeftFoot]

Are you sure it isn't a diesel leak that is washing engine oil down the engine?

Question is.. where will it be leaking from? Spill rail is not leaking.

 

[Turboman]

Question is.. where will it be leaking from? Spill rail is not leaking.

It could be some distance away from where you are seeing it. Hot diesel runs all over the place. Try smelling the liquid that is dripping.

 

[LeftFoot]

It could be some distance away from where you are seeing it. Hot diesel runs all over the place. Try smelling the liquid that is dripping.

Everywhere else is dry. It is definitely coming from around injector housing.

 

[Turboman]

Everywhere else is dry. It is definitely coming from around injector housing.

What exactly do you mean by injector housing?

 

[LeftFoot]

What exactly do you mean by injector housing?

The hole the injector goes into.

 

[LeftFoot]

Can this problem be a sign of worn piston rings/ oil seal? I am lost as to where all of this oil is coming from. And only from one injector port whereas the others are dry.

 

[Turboman]

Can this problem be a sign of worn piston rings/ oil seal? I am lost as to where all of this oil is coming from. And only from one injector port whereas the others are dry.

The injector shrouds are pressed into the head, there will be some kind of seal around them, if it is leaking, oil or water will leak out.
I am not very familiar with 300 TDi, but that is the general rule on diesels.
Alternatively, if the injector is leaking diesel down in the head, that could be running out, and diluting carbon around the base of the injector, which will be there due to faulty sealing of the injector tip.

 

[discomania]

300tdi
Engine reading 90,000 miles

Issue: Oil running from injector #2 housing despite two attempts at sealing it using brand new copper washers.

When injector #2 is removed the body is covered in oil whereas the other 3 injectors are only coated with fuel when removed.

The images attached compares injector #1's housing to injector #2's after a short drive. The oil is running out at such a high rate it quickly finds its way down to my driveway which is quickly becoming a mess.

Is this bad news? I have a theory what it is but I would like to hear your opinions please..

I doubt that is oil coming up past an injector as there should not be any quantity oil down there! Maybe sooty diesel but that would be chuffing and blowing out spraying sooty diesel everywhere.

However, looking at those leaks I expect it might be the rocker cover seal - often is. They can be a pig to get to seal properly due to the bad 3 bolt design - the way the seal works and the low torque value (10Nm) allows the seal to sit up, then you torque it down and as you go along doing it in stages and in sequence it will pull one side down to 10Nm, the rocker cover then rides up a fraction on the other side, the next bolt then gives a false reading of torque because the cover has see-sawed and you also have some friction on the bolt etc. etc. It's a pig. Even taking your care and applying all the engineering tricks in the book as used on flanges and cover plates and all sorts... they still tend to leak a bit. Also, the covers can warp - I had one that would not seal - took it off and checked the sealing face for flat it was like a banana!

 

[discomania]

Rocker cover seal replaced the same time as injector seals. Area was cleaned and all hoses in good condition. Can this oil not be blowing past the seal? Remember when the injector was removed it was coated in oil.

Not oil, sooty diesel. Unless you have another issue, i.e. oil getting into cylinder (more than usual lubricating film).

 

[discomania]

Are you sure it isn't a diesel leak that is washing engine oil down the engine?

There is a reasonable possibility of this too.

 

[Turboman]

There is a reasonable possibility of this too.

I imagined as much, I have commonly seen both on other engines. Unfortunately, my own experience of Tdi is limited. I tend to stick to indirect injection, which I know much better.

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