R

Richyrich06

Member
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
 
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.
 
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
upload_2023-1-29_9-28-30.jpeg
 
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
Click to expand...
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?
 
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?
Click to expand...
New copper washers and correctly torqued to spec...
 
Last edited:
Richyrich06 said:
New copper washers and correctly torqued to spec...
Click to expand...

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

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.
 
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.
Click to expand...
Official Bosch washers on way... Fingers crossed..
Cheers
 
if you've none ..
get some:
Febi Bilstein Special Ceramic Grease | 26712
( Grease for fuel injectors / glow plugs. )
.
 
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.
 
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
 
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
 
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
Click to expand...

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?
 
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.
 
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?
Click to expand...

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
 
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