V50 Engine 2.0D : Excessive smoke, Help needed

[daveyonthemove]

Car is now booked in with an injector specialist on tuesday. They are going to re-seat the leaking injector for me at £15 + VAT and labour for removal/fitting of injector.
I'm hoping that this will sort the problem once and for all and I can finally drive the damn thing, because right now it's just a shelter for insects.

[paddyred]

Any news Davey? Was it fixed?

[daveyonthemove]

Originally Posted by paddyred

Any news Davey? Was it fixed?

Injectors 1 and 2 were reseated but the problem persists..
I also discovered that 3 of the 4 supposedly 100% working injectors have leaks or won't accept the leak off pipe, so I've informed the seller that I want a refund and he has chosen to ignore me.
Original injectors are going to be sent off for a refund.

[Bloders2]

so, which injectors are in it now?
have you tried it with different injectors?
have you had yours tested?

I think the answers are yours, no and no? Im tired and prone to reading stuff wrong)
if this is the case, you still have not ruled the injectors out.

Whilst typing, a question has occured to me. Im sure youve answered it.
How does it drive? plenty of power or not so good?

It needs a leak down test doing.
Remove all glow plugs
Turn piston to TDC and lock engine (top gear, assistancts foot HARD on the brake)
Put compressed air into each cylinder in turn via the glow plug hole.

you will be testing that the valves are closing and seating properly, and more informative than a compression test.
You could have a leaky valve(s) leading to unburnt fuel?
could you have bent con rod, so not getting proper compression?
Test by removing injectors, and in turn measure the distance when TDC from piston to a know point on head. All should be exactly the same.

Do you have correct turbo pressure? (i think you do as you have replaced MAP and MAF sensor)

after that, ill need another beer to think it through more. short of stripping the top end down im running out of ideas here.

[daveyonthemove]

Originally Posted by Bloders2

so, which injectors are in it now?
have you tried it with different injectors?
have you had yours tested?

I think the answers are yours, no and no? Im tired and prone to reading stuff wrong)
if this is the case, you still have not ruled the injectors out.

Whilst typing, a question has occured to me. Im sure youve answered it.
How does it drive? plenty of power or not so good?

It needs a leak down test doing.
Remove all glow plugs
Turn piston to TDC and lock engine (top gear, assistancts foot HARD on the brake)
Put compressed air into each cylinder in turn via the glow plug hole.

you will be testing that the valves are closing and seating properly, and more informative than a compression test.
You could have a leaky valve(s) leading to unburnt fuel?
could you have bent con rod, so not getting proper compression?
Test by removing injectors, and in turn measure the distance when TDC from piston to a know point on head. All should be exactly the same.

Do you have correct turbo pressure? (i think you do as you have replaced MAP and MAF sensor)

after that, ill need another beer to think it through more. short of stripping the top end down im running out of ideas here.

There are no injectors in it right now, but i will be putting my original ones back in.
I did buy 4 replacement (used) injectors and replaced all, however:
Number 1 injector leaked and also wouldn't seat correctly (seating fixed).
Number 3 injector wouldn't accept the leak off hose, so had to be replaced with one of my original injectors (who knows if I put a dodgy one back in, or had 3 other dodgy ones?).

Garage re-seated two of the injectors but having driven it less than one mile back from the garage there was a strong smell of diesel, and inspection showed that two of the injectors were leaking.

So that's 3 confirmed faulty injectors and I never had a chance to drive it far for obvious reasons, so injectors are not rued out yet.
Faulty injectors are being sent back, and original injectors are going to be sent off for a refurb.

If they come back working as they should (will have a report with them) I'm hoping it will cure the issue.
If not, the fuel injector pump is a possibility.

Beyond that, it's going to have to go into a garage as it's beyond my skillset and socket set.

The car drives well and pulls as it should but the smoke is ridiculous.

[paddyred]

I am guessing the circled bit is where it leaked from. I am surprised it leaked from there. The leak off pipes usually leak not the HP line (I drove for 4 months with a pool of diesel on the head because I couldn't be bothered to fix it.) The diesel has a habbit of wicking up the rust on the injector and going around that area and around the HP pipe making it look like they are leaking when they aren't. What you need is a proper way to test the HP fuel pump output pressure, should be around 300 bar IIRC.
This is getting ridiculous with the smoking issue now. I would check the fuel pump and if it isn't that then start from the basics again. Have you had the engine compression tested etc?

[daveyonthemove]

Originally Posted by paddyred

I am guessing the circled bit is where it leaked from. I am surprised it leaked from there. The leak off pipes usually leak not the HP line (I drove for 4 months with a pool of diesel on the head because I couldn't be bothered to fix it.) The diesel has a habbit of wicking up the rust on the injector and going around that area and around the HP pipe making it look like they are leaking when they aren't. What you need is a proper way to test the HP fuel pump output pressure, should be around 300 bar IIRC.
This is getting ridiculous with the smoking issue now. I would check the fuel pump and if it isn't that then start from the basics again. Have you had the engine compression tested etc?

Not yet, i'm trying to do all the work I can do myself before leaving it with a garage.

[paddyred]

Well hopefully it gets sorted. You might want to check the exhaust back pressure. If you have a DPF it could be failed, the back pressure could mean you have exhaust gas sat in the piston causing a dirty burn and raising combustion temps.

[daveyonthemove]

DPF was guttted within a few days of collection.
That was my first thought, but it's made no difference.

Once I get my refund for the faulty injectors I will take the car to a specialist and ask them to get to the bottom of it.
I'm running out of patience and I haven't had a single long summer drive in it yet, and that was the big appeal of this car to me.

[paddyred]

The worst thing is its bound to be something tiny and stupid that has been overlooked!