BennehBoy's D2 adventure

Bennehboy · May 13, 2016

Yeah the non return valve has a duck billed piece of orange rubber in it - I checked the new one before fitting.

I'll set about destroying the old one in a moment and take some pics if it includes the non return valve, the early ones didn't, they just had the air bleed valve on the other side.

Bennehboy · May 13, 2016

So I managed to get them all out - I was worried that I'd snap the housing when I tried this on the vehicle so wasn't as brutal...

Non return left, air bleed right

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Non return is clearly not true any more, I can see daylight through the 'lips' which are now well and truly pursed when they should be together.

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Air bleed valve is totally blocked up with soot and crap

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No wonder I was beginning to have trouble starting it, the fuel must've a) been leaking back to the tank, b) the air wasn't being efficiently expelled

raywin · May 13, 2016

That seems to hit the nail on the head, you have found two things which must have been giving you the grief, also if the copper injector washers leak it would let the combustion gas pass the injector and go into the fuel rail, that would account for the soot and muck in the bleed and n/r valve.
Can't wait to get mine open now. Wish you could buy the red rubber bit.

Bennehboy · May 13, 2016

raywin said:
That seems to hit the nail on the head, you have found two things which must have been giving you the grief, also if the copper injector washers leak it would let the combustion gas pass the injector and go into the fuel rail, that would account for the soot and muck in the bleed and n/r valve.
Can't wait to get mine open now. Wish you could buy the red rubber bit.

Yeah imagine being able to buy only what you need,

Bennehboy · May 17, 2016

Forgot to add that I'd fitted the Bailey Morris prop, it's about twice the weight of a stock one, very impressed with it.

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Bennehboy · May 22, 2016

Well, bit of a minor disaster.

Car started to run rough as arseholes.

Figured I'd stuffed up the injector seals.

Swapped them all out again, except when I got to pot 5 I had managed to misplace the new washer (long story it blew down between rad and intercooler).

In my rush I decided to leave 5 as is and reassemble. Dickhead here forgot to tighten the clamp on injector 5.

Pressurised fuel rail with a purge - this must've lifted the injector and filled the cylinder with fuel at whatever height it was at (not TDC).

Started engine, small bang - which at the time I thought was a tool dropping off the front valence.

MASSIVE plume of white smoke out the back, and running even rougher.

Found the seal eventually, fitted it (and found my mistake with the clamp bolt), fired it up and same issue.

So, looks like I either killed an injector or bent a conrod

Picking up a spare injector today, will try that, if no change, will measure piston heights on no4 & no5 via the injector bore.

Just priced up the parts to replace the conrod from Turners, about £260.

Egg on face.

jamesmartin · May 22, 2016

Bennehboy said:
So I managed to get them all out - I was worried that I'd snap the housing when I tried this on the vehicle so wasn't as brutal...

Non return left, air bleed right

Non return is clearly not true any more, I can see daylight through the 'lips' which are now well and truly pursed when they should be together.

Air bleed valve is totally blocked up with soot and crap

No wonder I was beginning to have trouble starting it, the fuel must've a) been leaking back to the tank, b) the air wasn't being efficiently expelled

have you had pump out of tank recently and checked the screens

raywin · May 22, 2016

Bennehboy said:
Well, bit of a minor disaster.

Car started to run rough as arseholes.

Figured I'd stuffed up the injector seals.

Swapped them all out again, except when I got to pot 5 I had managed to misplace the new washer (long story it blew down between rad and intercooler).

In my rush I decided to leave 5 as is and reassemble. Dickhead here forgot to tighten the clamp on injector 5.

Pressurised fuel rail with a purge - this must've lifted the injector and filled the cylinder with fuel at whatever height it was at (not TDC).

Started engine, small bang - which at the time I thought was a tool dropping off the front valence.

MASSIVE plume of white smoke out the back, and running even rougher.

Found the seal eventually, fitted it (and found my mistake with the clamp bolt), fired it up and same issue.

So, looks like I either killed an injector or bent a conrod

Picking up a spare injector today, will try that, if no change, will measure piston heights on no4 & no5 via the injector bore.

Just priced up the parts to replace the conrod from Turners, about £260.

Egg on face.

Christ Ben you are having some bad luck, is your house built on an old Indian burial ground?
Sounds like you need to pull it down and find what is really wrong before gouging any further,
Might be an idea to speculate and grab something like this just in case :
http://www.ebay.co.uk/itm/Set-Of-5-...956077?hash=item1a134ce4ad:g:GqEAAOSwe8tXMiNQ
If worst come to the worst I have a piston con rod in the garage I got from Arron a while ago, I was saving it in case of any problem when I do my rebuild, but looks like a n emergency here.

Bennehboy · May 22, 2016

jamesmartin said:
have you had pump out of tank recently and checked the screens

Brand new VDO pump James, the old one failed, that's what started this whole affair. If I get the same problem with the injector I just collected, and then the piston heights are the same, then I'll get a pressure gauge on the FPR and see what's being delivered.

Bennehboy · May 22, 2016

raywin said:
If worst come to the worst I have a piston con rod in the garage I got from Arron a while ago, I was saving it in case of any problem when I do my rebuild, but looks like a n emergency here.

Very kind of you, I may be in touch if it comes to it.

jamesmartin · May 22, 2016

was old pump partly blocked or is it combustion gasses

Bennehboy · May 22, 2016

The £260 includes sump gasket, head gasket, head bolts, conrod itself, bearing shells BTW. Save about £100 ish if I used a 2nd hand rod.

Bennehboy · May 22, 2016

jamesmartin said:
was old pump partly blocked or is it combustion gasses

Dead motor, but the pump and filters were pretty black, could've blacked up at any point in the past but I decided to do injectors anyhow - as it happened they didn't look too bad, no pitting on the washers. Bad move

Bennehboy · May 22, 2016

Gonna go try this spare injector now - long shot I think, but fingers crossed.

raywin · May 22, 2016

Bennehboy said:
The £260 includes sump gasket, head gasket, head bolts, conrod itself, bearing shells BTW. Save about £100 ish if I used a 2nd hand rod.

I would not hesitate to use a 2nd hand con rod if it is not bent, they are not really subject to wear and are usually well over engineered.

jamesmartin · May 22, 2016

Bennehboy said:
Dead motor, but the pump and filters were pretty black, could've blacked up at any point in the past but I decided to do injectors anyhow - as it happened they didn't look too bad, no pitting on the washers. Bad move

shiny unbroken by black stain ring on washer, you find a lot of black with the diesel bug common in td5s

Bennehboy · May 22, 2016

Job jobbed.

Looks like I'd killed the injector, or it was a very unlikely coincidence.

Running fine with the new injector in.

Just need to keep an eye on oil levels now - I didn't refresh the o-ring and seal on this one, they looked to be in great condition.

Performance is back, no smoke trails, idle balance could be better but highest any is going is +-6 and typically remaining lower.

Bennehboy · Jun 3, 2016

Well, spoke too soon.

Still got crap idling, but it comes and goes, sometimes it's perfect, but most the time is poor.

I've put new seals on the replacement injector.

I've checked the gauze filter behind the FPR.

I've put the old injector loom on.

No change.

Got another full set of seals arriving in the post which I'm going to anneal before fitting. If it's still not right then the head's coming off.

Bennehboy · Jun 12, 2016

Sorted the idling, injector 2 wasn't sealed correctly - could see on live data that it was the one consistently throwing the high values. Annealed a new washer and it's now good.

Injector 3 looks like it may also need some attention but the values are all sub 10 so it's waiting whilst I sort out some more important stuff...

So, need to find a good bodywork firm to sort the nearside footwell rot.

Also turned my attention back to the axle rebuild, so went out and got some 8 foot sleepers chopped up yesterday to make some chassis blocks:

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Bennehboy · Jun 14, 2016

Fabbed up one of the Chassis blocks. This bit all bolted together, height shimming will be done atop this with other blocks.

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Hoping to get cracked on with the swap this weekend coming - fingers crossed for reasonable weather!

BennehBoy's D2 adventure

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