hi there
my 440 TD was stuttery for a few days then when I borrowed it from my wife for a day it stalled as I slowed down. I ignored it, thinking it was my bad clutch control but after two more times on the sy home I was concerned
Im used to working on petrols so working on the 440 was a steep learning curve. the csr would fire but would stall right away, especially once you revved it
I bypassed the fuel cut of solenoid (on the pump) and the cold start actuator (this solenoid allows a vacuum line to be supplied to the cold start timing advance lever and the vacuum pulls it to the right for cold starts). by running a positive feed to each solenoid I was able to check that they were alive and well and by maintaining connection I could eliminate poor connection or incorrect functioning control unit (the one on the bulkhead controls the glow plugs using info from the temp sensor. glow plugs ae heated during the glow plug light being on but also for some time afterwards depending on outside temp. the cold start vacuum acuator is also controlled by this unit (solenoid is mounted on the bottom of the battery plate btw)
bypassing both and the car started for longer than usual. revving, it was ok too. quite smoket though
it didnt last though
the priming pump button is a connected to a flat diaphram. In my car, this was leaking so when you pushed to pump, fuel spilt out of the top but also from the filter sealing O rings (large ones supplied with the new filter)
if air can get in the priming pump is affects the fuel dosing at the injectors and fuel pressure
During 1st 2-3 mins of start up it is normal for the engine to exhibit a little diesel knock or what I think sounds a mixture of clattering and gargling! This is due to the advance timing during cold starts. during this time also the exhaust may well be a bit more smokey. driivng off during this time also gives a little smokey exhaust. like during a petrol with the choke out really!
after max 5 mins the smoke disappears and the cold start actuator (via solenoid) should now be closed.
if once warm you car is smokey Id suspect either the timing is out (lucas pumps are set at the factory but can still be checked. bosch ones are easier. haynes needed is a renault 19 diesel but it isnt 100% the same so ideally a volvo service manaul is needed. some chaps in the club do have them. I was 99.9% going to get one till we found the leaking priming pump letting in air and causing all the problems!! alternatively, you may have a lazy injector which isnt closing and overfueling. This is more of a problem given that diesel causes more oil wahsdown the bores (it basically dilutes and thins the oil more successfully that petrol) which if unchecked causes one bore to wear more than another.
further, the smoke could be from a turbo oil seal which is on the way out.
thing is, both causes can result in smokey exhaust on acceleration
oil tends to be blue, excess fuel also gives a blueish tint smoke so a bit tough to separate.
also might be worth checking the intercooler. if it is unhealthy full of oil this shows turbo seal leaking (oil fils the intercooler) and if full enough could contribute to fuely exhaust as the oil is adding to the intake air/fuel mix.
glow plugs only afect things when the car is cold
you dont need to take the pump off to change them
diesels of this type and age do smoke under hard acceleration. indeed, you even see common rail diesels sooting when accelerating! only the very latest diesels with particulate filters and careful engine management software dont smoke at all.
a little smoke as you put your foot down is ok, its a calibrated eyeball to know if the car is excessively misbehaving
I'd get the timing check but before that, change the fuel filter and the priming pump top as these are more simple causes to the problem. also start the car cold and check the lever for the cold start advance is pulled by the vacuum line. watch the car warm up and make sure this moves in eventualy. max should be 10 mins but prob moved in by 5mins (depends on temp outside of course!)
if ou have a bosch pump most of what I've told you doesnt apply
bosch pumps are more durable and I believe the timing can be adjusted during the cars life. Lucas / CAV are harded to do. if you change from bosch to lucas CAV, the control unit on the bulk head needs changing, temp sensor, (i dont think the bosch has the vacuum cold start solenoid). glow plugs prob can stay but a check in a parts book for the 440 TD will tell you if it lists two parts ie one for lucas and one for bosch
The one used my friend sourced. Ive found the companies website but it doesnt have an english section. I paid 50p for mine. If you want I can post it to you? or ask a local parts factors to order the diaphram for this pump. NB shared part with the renault 19 1.9 TD! fuel filter is the same as a ford transit mk 1 also. (as is the air filter!)
to change the priming pump top you'll see the current one has metal tabs tha t fold around the housing. the old ones needs to be bent off - best to hold the housing in a vice when you do this. to install the new, place on top of the housing the bent round or down the metal tabs and it seals
the car gets 50mpg in town and only 70mpg when you stick to 60mph on motorway and resist the urge to ride the torque curve or the turbo! its fun when that comes on stream above 2000rpm!!
good luck and keep us posted!!
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