Freelander 1 Facelift TD4 White / Grey smoke issue

Richyrich06 · Jan 28, 2023

The issue : starts fine no real smoke, after a short while white grey smoke emits, strong diesel smell if rev plumes of smoke emit ....
I bought this a while back. very black smoky on start up and under load.
Found spilt in intercooler pipes so replaced, found blocked pcv filter so replaced with upgrade
still smoky so got recon injector set
It runs beautifully just seems to be badly overfuelling..
Any ideas please, pulling my hair out now

andyfreelandy · Jan 28, 2023

Sounds like over fuelling. Mine did similar and was a failed HP pump seal spraying high-pressure diesel vapour into the crankcase and then white plumes of smoke.

Not sure how to check this for sure except service the pump and regulator seals.

Nodge68 · Jan 28, 2023

Richyrich06 said:
It runs beautifully just seems to be badly overfuelling..
Any ideas please, pulling my hair out now

Have you checked all the boost hoses for splits and holes?

Richyrich06 · Jan 28, 2023

Nodge68 said:
Have you checked all the boost hoses for splits and holes?

All checked and new silcone ones fitted where required...

hd3 · Jan 28, 2023

it's evidently rare .. but sometimes a failed maf-sensor can cause overfuelling,
according to rover-ron's info .. [ https://www.tuning-diesels.com ]
.. underfuelling is the usual symptom ..
.

Richyrich06 · Jan 29, 2023

Hi all
pulled injectors yesterday, This is what they looked like. It hasnt driven anywhere for a while but run until up to temp...
Any ideas

Nodge68 · Jan 29, 2023

Richyrich06 said:
Hi all
pulled injectors yesterday, This is what they looked like. It hasnt driven anywhere for a while but run until up to temp...
Any ideas
View attachment 282065

The copper seals haven't been sealing, which will cause low compression, black death on the injector body, and incomplete fuel burning.
Were new seals used, and were the injector clamps correctly torqued?

Richyrich06 · Jan 29, 2023

Nodge68 said:
The copper seals haven't been sealing, which will cause low compression, black death on the injector body, and incomplete fuel burning.
Were new seals used, and were the injector clamps correctly torqued?

New copper washers and correctly torqued to spec...

Nodge68 · Jan 29, 2023

Richyrich06 said:
New copper washers and correctly torqued to spec...

What's the condition of the seat in the head? Something is causing the copper washer to leak, which is why the injector is covered in burnt diesel.

It may be that the seat in the head is damaged and needs cutting back a tiny amount, or it could just need a thorough clean with a brush and brake cleaner.

I've also had very hard washers in the past, which aren't annealed properly. If this is the case, it's prudent to anneal them again before fitting, just to ensure they fill any imperfections in the sealing surfaces.

Richyrich06 · Jan 29, 2023

Nodge68 said:
What's the condition of the seat in the head? Something is causing the copper washer to leak, which is why the injector is covered in burnt diesel.

It may be that the seat in the head is damaged and needs cutting back a tiny amount, or it could just need a thorough clean with a brush and brake cleaner.

I've also had very hard washers in the past, which aren't annealed properly. If this is the case, it's prudent to anneal them again before fitting, just to ensure they fill any imperfections in the sealing surfaces.

The head faces look lovely and clean and shiny smooth... The copper washers seemed hard and dont have the indents in the middle that they normally do..

Nodge68 · Jan 29, 2023

Richyrich06 said:
The copper washers seemed hard and dont have the indents in the middle that they normally do.

That is likely the issue. You should see witnesses marks on the washers where it was crushed between the injectors and the head. If there's no deformation of the copper, then a proper seal can't take place.

Richyrich06 · Jan 30, 2023

Nodge68 said:
That is likely the issue. You should see witnesses marks on the washers where it was crushed between the injectors and the head. If there's no deformation of the copper, then a proper seal can't take place.

Official Bosch washers on way... Fingers crossed..
Cheers

hd3 · Jan 30, 2023

if you've none ..
get some:
Febi Bilstein Special Ceramic Grease | 26712
( Grease for fuel injectors / glow plugs. )
.

Richyrich06 · Feb 1, 2023

Oh well..
Back to the drawing board...
New washers etc fitted. Issue as before ...
Any more ideas welcome ...

andyfreelandy · Feb 1, 2023

Don't give up !!
When my TD4 overfuelled, it took many hours of running to get the unburnt fuel out of the system and exhaust.
Use it, carefully, for a few hours and check again.

I had just fitted a new HP pump and it smoked like a train - makes you feel crap but it might just clear, it did for me.

Richyrich06 · Feb 5, 2023

Update.
Bit the bullet and pulled injectors and took to Bosch injector guys who tested them and said they were all bad, some sticking open some over fuelling.. So I messed up by using a refurbishing company of unknown quality.
They are replacing the needles and nozzles at great expense but I will end up with good injectors..
Whilst waiting I will thoroughly clean fuel system.
Heres hoping this solves the saga
Cheers for all your help

Richyrich06 · Mar 6, 2023

Back to the drawing board.
New injectors, New HP Rail pressure sensor
What else can cause over fuelling. Can the HP Pump Failing cause this OR ?
Please help, getting rather fed up with this thing now..
Cheers

Nodge68 · Mar 7, 2023

Richyrich06 said:
Back to the drawing board.
New injectors, New HP Rail pressure sensor
What else can cause over fuelling. Can the HP Pump Failing cause this OR ?
Please help, getting rather fed up with this thing now..
Cheers

Are you able to measure the rail pressure?
Have you checked the intake manifold for carbon build up?
Are all the boost hoses in perfect condition?

andyfreelandy · Mar 7, 2023

HP pump seals failing can squirt fuel into crankcase and so over fuel. Had this on a 2002 TD4. Also made it run on after switch off.

Richyrich06 · Mar 7, 2023

Nodge68 said:
Are you able to measure the rail pressure?
Have you checked the intake manifold for carbon build up?
Are all the boost hoses in perfect condition?

I did measure the rail sensor voltage and it seemed to give the voltage suggested (Fitted new HP sensor too)
I have cleaned all coke from manifold etc
I have changed all normal hoses for silicon

Freelander 1 Facelift TD4 White / Grey smoke issue

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