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S40 2.0 Diesel D4204T White smoke... Blown Head Gasket?...

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Old Dec 8th, 2019, 11:39   #1
guido
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Default S40 2.0 Diesel D4204T White smoke... Blown Head Gasket?...

Hi all, I'll try and keep this as brief as possible... I have a 2010 Volvo S40 with the 2.0 Diesel D4204t with 140k miles blowing white smoke. I recently bought this knowing about this issue but was told it was most likely a blocked DPF. The following work has been done recently:
-DPF removed and cleaned in Wynn's off car DPF cleaner (came up spotless) and a new rear muffler and tailpipe was fitted. Didn't change the cat but seems ok and exhaust pressure reading through Vida are around 3hPa. Eloys fluid was also refilled and after resetting in Vida it's showing the tank as full
-EGR valve and cooler were checked and are both clean. Both are aftermarket parts (Delphi and valeo) so appear to been replaced recently. I also tried a blanking plate but it made no difference
-A reconditioned turbo had been fitted just prior to purchase, they didn't give a receipt but it looks shiny and fresh
-i have replaced the high pressure injection pump and pressure sensor and Vida is showing around 280,000 hPa pressure which is correct according to Vida info guide.
-i had the injectors tested and all were reported as bad. The tester said they were all delivering about 40% more fuel than they should which would explain white smoke although the car started first time without issue.
-i have some supposedly good injectors off fleabay and the smoke has reduced by quite a bit but I still get white clouds when revving the engine.
-car has fresh oil and coolant was drained/replaced and the expansion tank was replaced as the cap was jammed in place (quite common from what I've read)
-all glow plugs and the relay were faulty and have been replaced
-Reset the ECU adaptation values in Vida and car is not showing any DTC codes. Injectors are also coded correctly

So the symptoms now are barely visible white smoke at cold idle (it's difficult to tell how much is from the engine and how much is the cold weather and condensation in the exhaust) but as the engine warms up the smoke gets thicker and revving produces thick white clouds. Coolant level has been slowly dropping and I've been topping it up but at the moment I'm not 100% sure if it's burning all of it or if there were some air pockets left from when it was drained/refilled. Clear liquid is also coming from the exhaust but the car is parked on a sloping driveway and it's quite cold so am not sure if it's coolant coming through or some condensation?

I have carried out a compression test using an old Sykes Pickavant diesel compression tester and a dummy injector (made from an old faulty injector with the internals removed and drilled out). All cylinders read indentically at just over 300psi.

I'm suspecting a possible blown head gasket although the engine oil is still clean and I'm not seeing any major bubbles in the coolant tank but there are a few tiny ones. The coolant still looks clean. I saw another thread with a similar issue and the owner reported a head gasket failure blown on the exhaust side although never followed up with specific details.

Does anyone know if there's any other places coolant can enter the exhaust system beside a blown head gasket? In light of the above does anyone have any other suggestions of what to check before removing the cylinder head?
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Old Dec 8th, 2019, 11:58   #2
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Originally Posted by guido View Post
Hi all, I'll try and keep this as brief as possible... I have a 2010 Volvo S40 with the 2.0 Diesel D4204t with 140k miles blowing white smoke. I recently bought this knowing about this issue but was told it was most likely a blocked DPF. The following work has been done recently:
-DPF removed and cleaned in Wynn's off car DPF cleaner (came up spotless) and a new rear muffler and tailpipe was fitted. Didn't change the cat but seems ok and exhaust pressure reading through Vida are around 3hPa. Eloys fluid was also refilled and after resetting in Vida it's showing the tank as full
-EGR valve and cooler were checked and are both clean. Both are aftermarket parts (Delphi and valeo) so appear to been replaced recently. I also tried a blanking plate but it made no difference
-A reconditioned turbo had been fitted just prior to purchase, they didn't give a receipt but it looks shiny and fresh
-i have replaced the high pressure injection pump and pressure sensor and Vida is showing around 280,000 hPa pressure which is correct according to Vida info guide.
-i had the injectors tested and all were reported as bad. The tester said they were all delivering about 40% more fuel than they should which would explain white smoke although the car started first time without issue.
-i have some supposedly good injectors off fleabay and the smoke has reduced by quite a bit but I still get white clouds when revving the engine.
-car has fresh oil and coolant was drained/replaced and the expansion tank was replaced as the cap was jammed in place (quite common from what I've read)
-all glow plugs and the relay were faulty and have been replaced
-Reset the ECU adaptation values in Vida and car is not showing any DTC codes. Injectors are also coded correctly

So the symptoms now are barely visible white smoke at cold idle (it's difficult to tell how much is from the engine and how much is the cold weather and condensation in the exhaust) but as the engine warms up the smoke gets thicker and revving produces thick white clouds. Coolant level has been slowly dropping and I've been topping it up but at the moment I'm not 100% sure if it's burning all of it or if there were some air pockets left from when it was drained/refilled. Clear liquid is also coming from the exhaust but the car is parked on a sloping driveway and it's quite cold so am not sure if it's coolant coming through or some condensation?

I have carried out a compression test using an old Sykes Pickavant diesel compression tester and a dummy injector (made from an old faulty injector with the internals removed and drilled out). All cylinders read indentically at just over 300psi.

I'm suspecting a possible blown head gasket although the engine oil is still clean and I'm not seeing any major bubbles in the coolant tank but there are a few tiny ones. The coolant still looks clean. I saw another thread with a similar issue and the owner reported a head gasket failure blown on the exhaust side although never followed up with specific details.

Does anyone know if there's any other places coolant can enter the exhaust system beside a blown head gasket? In light of the above does anyone have any other suggestions of what to check before removing the cylinder head?
maybe the EGR cooler ? take off the shiny EGR pipe going to the manifold and see if there are white deposits inside ..
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Old Dec 8th, 2019, 20:39   #3
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Not sure if relevant or not, but when my lads motor (not Volvo) had the Turbo go, we changed it, but there was SO much oil in the silencer wadding (even drilled and drained excess) , we had to change the Silencer and run it around for some time before it cleared.
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Old Dec 8th, 2019, 20:54   #4
guido
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Thanka for the replies. I got under the car again today and there is a bit of oil on the pipes near the turbo but I think one of the jubilee clips was a bit loose so I've tightened them up and wiped the excess away and will keep an eye on it.

I rigged up a bypass loop using bits from my plumbing spares box to remove the coolant flow from the EGR cooler and also blanked off the EGR valve with a blanking plate and disconnected the wiring plug. It was looking promising for a while, fired it up and couldn't see any white vapour/smoke for around 5-10mins but as it warmed up and with a few revs it started again. Small amounts of water also comes out of the exhaust pipe when revved and I think it's more than condensation

I've not pressure tested the cooling system yet but not sure if there's much point as all other signs seem to point towards thr head gasket (or worse).

It's looking like the head will need to come off....unless anyone has any other ideas?

Head gaskets seems to be cheap enough for this engine but am not looking forward to hours standing out in the cold on my driveway
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Old Dec 10th, 2019, 01:30   #5
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Just a quick update... I thought I'd try some K-Seal before taking the head off. Seems to be lots of good feedback so thought it was worth gambling a tenner. I'm happy to say that the white clouds have all but disappeared and it's not losing coolant. I've only done about 20miles so will have to see how it goes but it certainly looks promising at the moment. Hopefully it will last long enough to make the head gasket repair a summer job
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Old Dec 10th, 2019, 10:26   #6
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Just a quick update... I thought I'd try some K-Seal before taking the head off. Seems to be lots of good feedback so thought it was worth gambling a tenner. I'm happy to say that the white clouds have all but disappeared and it's not losing coolant. I've only done about 20miles so will have to see how it goes but it certainly looks promising at the moment. Hopefully it will last long enough to make the head gasket repair a summer job
K Seal is the best , it sealed the bottom of a cylinder liner in one of my engines 10 years ago , still not leaking ..

In your case it is worrying not knowing where the leak is , your engine doesn't blow headgaskets unless severely overheated ..
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Old Dec 15th, 2019, 17:42   #7
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guido how is your car doing? any steam/smoke? hows the coolant level
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Old Dec 22nd, 2019, 23:45   #8
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K Seal is the best , it sealed the bottom of a cylinder liner in one of my engines 10 years ago , still not leaking ..

In your case it is worrying not knowing where the leak is , your engine doesn't blow headgaskets unless severely overheated ..

I am also very keen to know where the leak is/was. I came across another forum where the owner reported a head gasket leak allowing coolant into the exhaust side. I'm guessing this was a similar issue as even before the k-seal went in there were no signs of water mixing with the engine oil and the coolant was clean. I was checking the coolant resovoir tank for bubbles but it was difficult to tell as the return hose attaches to the top of the vessel and flows down the side.

The car had a recon turbo fitted just prior to purchase in an attempt to fix the smoke issue. The diesel specialist that tested the injectors said it was odd that all the injectors were bad and also noticed they had blueish tips. He said it was possible that when the turbo failed some oil made its way into the cylinders causing the engine to runaway and overheat also causing head gasket failure. It's just a theory but he seemed to think it was likely.

Either way I've been doing around 60 miles per day for the past two weeks and it's all good. No smoke at all and it's not burning any coolant or other fluids.
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Old Dec 22nd, 2019, 23:51   #9
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guido how is your car doing? any steam/smoke? hows the coolant level
I've been doing around 60 miles a day for about two weeks and it's all good. No smoke at all and the coolant level hasn't moved since the k-seal worked its magic. It's had a mixture of motorway, stop/start traffic, steep hills and some 'spirited' driving mixed in. I keep checking my mirrors waiting to see that big vapour cloud but it hasn't happened yet
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Old Dec 23rd, 2019, 21:48   #10
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We've put k seal in and it's not worked. We called them and they were surprised and are sending us a free bottle.
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