White/black smoke won't rev 135 T350 2.4TDCI

[Excudo]

Hello everyone,
I bought a Ford Transit T350 2.4 TDCi with an engine that was not running. The problem turned out to be related to the timing. There was a camshaft sensor fault. After inspection, it was found that the timing chain had stretched and the tensioner had reached its maximum extension. The intake camshaft sprocket was out of timing by four teeth, which was causing the fault.
The engine now starts perfectly, but it produces a lot of smoke.
I have tried several different things, but I still can't find the cause.
The injectors were tested by a diesel injection specialist, found to be faulty, and then rebuilt. They are now OK.
Injector coding has been checked.
The fuel pressure regulator solenoid on the injection pump was replaced.
No DTCs are present during diagnostics.
The engine behaves exactly the same with the intake pipe removed, so I don't think the turbocharger or the EGR valve is the cause.
The smoke is also the same with the exhaust disconnected.
The smoke doesn't smell like oil and it isn't blue, so I don't think it's an oil-related issue.
The cooling system is currently empty because I had to remove the entire front end of the vehicle.
I think it may be a fuel injection problem, but I'm running out of ideas.
I've found many topics describing the same problem, but I never found the actual solution. Can anyone help me?

[Airthies]

Did you do a compression test to check valves were ok once timing chain was replaced?

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[Excudo]

No, I was actually thinking about that. I removed the valve cover to check for any visible damage, but I couldn't find anything.
Do you know what pressure value I should be getting?

[metalworker0]

300 would be the bottom limit .. and anything over 340 would be good .. with a difference of less than 10 percent between cylinders.

i don't know if you have a failed head gasket .. and its sucking in anything that left in the block .. as you say its empty.

all the best.mark

[andz327]

stretched by 4 teeth and no valve damage ??


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[metalworker0]

bet it sounded like a bingo machine
https://www.youtube.com/watch?v=XtSZQH0cBFY


all the best.mark

[knobby1]

Hello everyone,
The intake camshaft sprocket was out of timing by four teeth, which was causing the fault.

Not possible without damage.

Lord Knobrot (Smithy)

[Excudo]

I'm surprised as well. When I bought the vehicle, the engine cranked over smoothly with no unusual noises.

After fitting the new timing chain and correctly timing the camshafts, the engine started instantly. It idles steadily, although there is a slight vibration, and there are no suspicious metallic noises.

I've read everywhere that broken rocker arms are common on this engine. When I removed the rocker cover, I didn't see anything abnormal. Everything appears to be OK.

I'm not sure how to check any further.

[knobby1]

I'm surprised as well. When I bought the vehicle, the engine cranked over smoothly with no unusual noises.

After fitting the new timing chain and correctly timing the camshafts, the engine started instantly. It idles steadily, although there is a slight vibration, and there are no suspicious metallic noises.

I've read everywhere that broken rocker arms are common on this engine. When I removed the rocker cover, I didn't see anything abnormal. Everything appears to be OK.

I'm not sure how to check any further.

They also break rocker shaft bolts or pull threads out of the rocker shaft carrier. The Mk6 is different to the Mk7 in that the Mk7 has a rocker ladder setup, the Mk6 has rocker shafts.

Mk6 here:

https://www.catcar.info/ford/?lang=en&l ... I3Mg%3D%3D

Mk7 here:

https://www.catcar.info/ford/?lang=en&l ... NisxMzM%3D

The Mk6 TDCi also has a cam sensor, if the inlet cam timing is out it will not fire the injectors.

If the cam timing was out more than 2 teeth, pistons will hit valves.

Lord Knobrot

[Excudo]

Mine is a Mk6 with the Duratorq Ultimate engine fitted with common rail injection. It's from before the Puma engine generation, which apparently has different common issues.

Indeed, when I bought the vehicle, it had a camshaft sensor fault. That's when I realized the timing was out.

I had read that if the rocker arms hadn't broken, everything should be fine. So I removed the rocker cover, and everything looked normal to me.

I've ordered a compression test kit for the engine. I should receive it next week. I'll keep you informed of the results.

[knobby1]

Mine is a Mk6 with the Duratorq Ultimate engine fitted with common rail injection. It's from before the Puma engine generation, which apparently has different common issues.

Indeed, when I bought the vehicle, it had a camshaft sensor fault. That's when I realized the timing was out.

I had read that if the rocker arms hadn't broken, everything should be fine. So I removed the rocker cover, and everything looked normal to me.

I've ordered a compression test kit for the engine. I should receive it next week. I'll keep you informed of the results.

If it's a Mk6 (2000-2006) with a TDCi Common Rail engine, it is a Duratorq "Puma" engine, they came in 125ps FWD and 135ps RWD....there's no such animal as a Duratorq "Ultimate" engine. Do you have a photo of it..??

Lord Knobrot

[Excudo]

Mine is a 2005 T135 RWD.

I thought the Duratorq engines were used up to 2006, and the Puma engines started from 2007.

I say "Ultimate" because before the TDCi engines, there were the DI engines without common rail injection.

Here are some photos of the engine.

[metalworker0]

Ok i see from the pictures your 4 teeth out .. not stretch .. chain has jumped cam sprocket.

causes are:
1. bump starting - see this post - viewtopic.php?f=5&t=141576

.2.. or tensioner not tensioning because of worn chain..; not so .. chain tensioner is not extended beyond its range .

but this is just comments on the original problem not its present problem .. well not if its present problem isn't related to damage caused by running 4 teeth out for any length of time .

Conclusion - do a compression test - needed NOW. before any other diagnoses

all the best.mark

[knobby1]

Mine is a 2005 T135 RWD.

I thought the Duratorq engines were used up to 2006, and the Puma engines started from 2007.

I say "Ultimate" because before the TDCi engines, there were the DI engines without common rail injection.

90% of the Mk6 Puma Engines were TDDi and not TDCi, the TDCi didn't start production in the Mk6 until the first 2.0L 125ps TDCi FWD in ~April/May of 2002, the 2.4 135ps TDCI began production in ~March of 2004. There is no official "Ultimate" Puma engine. Many believe the Mk6 TDCi engines were temperamental and the fuel systems were unreliable....but when they were running well, they were indeed a good thing.

The Duratorq "Puma" engine began at the beginning of 2000 on the first Mk6 2.0 and 2.4 TDDi's & the later TDCi's through to April of 2006 when the Mk7 began with the 2.2 & 2.4 and into the last of the Puma 2.2's of the Mk8 produced up to ~May of 2016. The 2.0L "Panther" engine was the successor to the Puma engine and I believe began production in ~May of 2016....and in many people's eyes the Panther engine was a step backwards with the silly wet cam belt setup.

So the "Duratorq Puma" engine ran for ~16 years and encompassed the Mk6, Mk7 and Mk8.

Lord Knobrot (Smithy)

[knobby1]

Mine is a 2005 T135 RWD.

Here are some photos of the engine.

The Mk6 TDCi engine has an inlet cam sensor, same as the Mk7's...if the inlet cam timing was out by just one tooth, it will not start or run, so I suspect your inlet cam "4 tooth" jump happened when it last stopped, we can see the chain is very loose at the top near the inlet cam sprocket....it could never have been running like this.

I wonder if your cam chain tensioner is stuck in or it's little "ratchet" is damaged..??

Lord Knobrot (Smithy)