andyfreelandy

andyfreelandy

Well-Known Member
So having put 10k miles on the TD4 Sport.
One annoying thing is a minor oil leak at rear of engine.

Impossible to see where from but it is certainly right at the top.
Also oil, not diesel, sitting around injectors.

Figured best bet is to clean and refurb a complete set of plastics, manifold, cam cover and new silicon hoses and replace the lot with a new gasket. I also see that sealer is advised in a few critical spots. So have a box of goodies ready to go on.

Fairly big job, all injectors have to come out.

While it is stripped down I can check condition as I go. I'm thinking maybe a crack in the cam cover. Can't see the gasket leaking?

Anyone done this job while engine in the car and any tips ??

Thanks.
 
Thanks. Yes that is not the source of this leak. It is along the rear of the engine near the bulkhead. Impossible to see even with a flexi camera but it is certainly at the very top.
 
If there's oil in the glow plug holes, then it does point to the cam cover gasket failing. It's a rubber gasket, which will shrink and harden over a couple of decades.
 
Spent a couple of hours on this today.
Stripped off all intercooler hoses as replacing these.
All plastic work and injectors and cam cover off.

What an oily mess. Definitely the gasket. What sort of pressure will be in the cam cover?
Looks like it has blown out of the back and showered the underside of the air filter case and the metal plate above the turbo.

The PCV filter had been changed just prior to purchase and I checked. What pressure does the PCV blow at ??

Also, the servicing garage, all stamps in service book is garage, decided that the long tail on the air filter lid was difficult to locate so they hacked it off. This means some oil has got into the back of the air filter housing as the hacking has left gaps and holes !!

So fitting all replacement items suitably cleaned up.

Will also replace the vacuum pipes while cam cover is off as you can get to the back of the engine much easier.

So. TO DO:
New filters, gasket (with the sealer where LR says it is needed), clean injectors and new O rings plus washers and cleaned intake manifold and silicone hoses. Then degrease and clean rear of engine and see what happens.

Will post some photos.
 
I'm thinking a blocked PCV previously caused the gasket to leak, which has gone hard, then even with a new filter it leaked.
 
20250129_104834.jpg20250129_104935.jpg20250129_105156.jpg

Oil around injectors, under air cleaner housing and the modified air cleaner cover letting in all sorts of things !!

This is the same garage that completely ripped off the lower front bumper section to access the under tray bolts and fixed the air grille with cable ties !! A couple of hours with a scrap bumper and heat gun and body panel bonding adhesive put that back to as it should be !!
 
Doesn't look too bad in photos. But I assure you !!

Will be stripping and cleaning PCV as there has been pressure here. About 3 to 6 psi I read is normal.
 
So all back together. Clean manifold. Clean but bypassed egr. Silicone boost hoses. Silicone vacuum hoses. New gaskets.

No oil leaks now. No oil from injectors either.

However, a very intermittent boost failure and P1470 appears.

As it is intermittent it can't be a hose problem as all new.
Thinking perhaps a wire disturbed on turbo solenoid or map sensor ??

When the fault isn't on it is perfect.

Going to be tricky to find but best to locate it now before driving to Scotland !!
 
Weirdest fault.
Checked all work done and hoses.
Cleaned electrical connectors on servo solenoid and MAP sensor.
No change. Boost falls off when pulling up hill. Managed to log manifold pressure on PScan and observe the drop.

Could find nothing wrong and so was ready to change turbo solenoid or MAP sensor, however, they worked fine before hose changes so unlikely to be faulty.

Reviewed what I have changed and because I wanted a clean set of plastics, I used a different manifold and air / boost pipe plastic.

Couldn't see anything wrong with the air / boost plastic, this is the one at the front of the engine bay with the air filter input and part of the turbo boost piping. However, out of desperation I refitted the old one.

Fault has cleared. Will it stay away? Has it cleared due to a warm engine after 3 or 4 test runs? Has it cleared itself?

Time will tell. If it is still clear in a week I will refit the other pipe arrangement and seen if fault comes back.

Have put bright light inside the boost pipe and can see no cracks, but it is possible under pressure I suppose.

One of the trickiest ever!!
 
Having had a read, what about if the turbo solenoid had always been faulty and over boosting. Now that all hoses are new and rigid then over boost is causing shut down ?.

Since I had it the turbo whistle seems to go on too long, but as it went like a rocket I left it alone.

I'm thinking this is more likely.

Views please ?!?!
 
Re-examined data. Inlet manifold pressure seems to max out at 248kPa.

Anyone know what max would be to cause EMS to limit things ??
 
1738444870859.png

Plot of RPM (horiz) against HP Fuel pressure and MAP pressure from PScan data log.
Shows, I think !!, when MAP hits 248 KPa the HP fuel pressure is cut dramatically to protect engine.

248KPa is around 36PSI
 
I'm afraid I'm nowhere near knowledgable to contirbute thoughts as to the possible causes of this one, but, I'm interested none the less so keep the updates coming.
 
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