MK 7 Engine Overhaul Journey

[Mark R]

I thought I would start this thread as it will be my journey in overhauling the rather badly running engine I've inherited, and hopefully will help others.

So bit of background, I bought a 08 Mk7 LWB knowing that it had engine issues....knocking, and black smoke once warm. My plan was to take out and replace the engine from one I saw advertised on fleabay, but my brother in law warned me of a few horror stories of people doing just that only to receive engines worse than the ones they had taken out! So this put me at a bit of a loss, Fortunately I hadn't paid much for the van(£200) so I thought I would try to find a local engine specialist and have this engine rebuilt. I started getting quotes in and again was at a bit of a loss as the quotes where quite high, at least in my eyes, one was £3500 plus the dreaded. I'm sure the work would be fantastic, but as getting a better van than the one I'd already got would be cheaper I've discounted this option for now also.

This leads me to next option starting with the cheapest the fuel system ie, the injectors. Now at this stage I want to get the injectors out and tested, and replaced if necessary. I will update once I've done this and report back, if this is daft or if anyone has a better option for my issue please jump in. Are the Injectors easy enough to get out? or should I ask a local garage, I'm happy to have a go myself but if they are a known pig to get out would rather get someone who knows

I was told by the seller, that he had been told that it had dropped a valve, but as he and his adviser don't have Xray eyes I'm optimistic that it isn't this and have buried my head in the sand . I had quite a few plans for this Van so hopefully I can sort it, the MOT runs out on my currant van in Feb so I've got a bit of time, TIA for any info or help.

All the best

Mark

[_Andy]

If its dropped a valve then you need to look into that before getting into the injectors. Does it turn over on the starter, or is it seized?

[lone wolf]

Looking forward to this thread, sadly i cant contribute but i will certainly learn as it goes along

£200 is a good price!

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[Mark R]

If its dropped a valve then you need to look into that before getting into the injectors. Does it turn over on the starter, or is it seized?

That's the strange thing it starts on the button and drives lovely, apart from the knocking and smoke, though to be fair there's only smoke once its warmed up or if I rev the engine.

[Mark R]

Looking forward to this thread, sadly i cant contribute but i will certainly learn as it goes along

£200 is a good price!

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I think the guy who sold it has become ill and wanted it off the books before he got worse poor chap he has MS, I just gave him what he asked for it.

[Airthies]

What ps is the van? I'm guessing it's a RWD 2.4?
Start by getting the codes read. Then checking if injectors are loose, and inspect all intake pipes.
Give it an oil and filter change, check/change air filter.

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[ned]

Black smoke is usually over fueling, is the knocking a diesel knock? You might have one or more injectors at fault.

[knobby1]

If it starts on the button and runs ok apart from a knock and smoke....it hasn't dropped a valve. Might just be something simple like poorly/loose injector clamps/copper seals.
How many miles on the beast..??
As mentioned by Airties, give it a good service/filters etc and go from there. There's plenty of helpful chaps on here to advise.

Lord Knobrot

[Airthies]

Also check turbo, if it's shot it won't be blowing enough air for the fuel it's getting

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[Mark R]

Lots to go on there, thanks chaps.

What ps is the van? I'm guessing it's a RWD 2.4?
Start by getting the codes read. Snip

Yes, it’s the RWD 2.4. I’ll see if I can get codes checked, at present van is off the road no mot, tax, or insurance so not easy to get things requiring a garage. That said my brother in law has his own garage, so may be willing to pop over.

Black smoke is usually over fueling, is the knocking a diesel knock? You might have one or more injectors at fault.

Weirdly I’ve had two garages give me conflicting stories one told me black smoke is an engine oil issue, meaning a rebuild. Another a fuel issue. Though both are diagnosing over the phone. I wonder if a short video of the engine sound, and the smoke would be helpful?

If it starts on the button and runs ok apart from a knock and smoke....it hasn't dropped a valve. Might just be something simple like poorly/loose injector clamps/copper seals.
How many miles on the beast..??

As mentioned by Airties, give it a good service/filters etc and go from there. There's plenty of helpful chaps on here to advise.

Lord Knobrot

The mileage isn’t ideal 250,000, that said 200,000 of those were tallied up driving to France.

I’ll report back when I’ve tried all the info received, thanks guys

[ned]

Oil is normally blue smoke, if you post a video to YouTube and put the link on here.

There are a few things you can do cheap and free, like Mr Airthies said, check all boost pipes for splits ect, and you could do an injector leak back test.

[mikeehlert1946]

If its dropped a valve then you need to look into that before getting into the injectors. Does it turn over on the starter, or is it seized?

That's the strange thing it starts on the button and drives lovely, apart from the knocking and smoke, though to be fair there's only smoke once its warmed up or if I rev the engine.

A compression check will tell you definitively if there is a dropped valve, bad rings, or other ills. Cheap too.


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[Mark R]

Thanks for all the info so far it's really been a help.

So this has taken a bit of a back seat as work has been crazy! But we have had a bit of progress today, the guy in the next unit was able to borrow a leak off test and this is the result of that..



He then set about getting the injectors out, this is what they look like..




What would be the best course of action now, refurbish the existing injectors or new ones??

[Airthies]

Hpw did you do your leak off test?
It's supposed to be measured at idle over several minutes and a leakoff quantity if between 20-40 ml
but can't remember time exactly
Looking at your test results (assuming it was done with the right conditions) it looks like left one is ok, middle ones are borderline and the right hand one is shot.
Look at replacing the worst one at least.

Clean injectors with brake clean and rag maybe a pointy scraper to get into the grove where the washer sits and where the end cap screws onto the body but DON'T put a wire brush anywhere near them!!!!!! Especially the tips, just clean them with brake clean round the outside leave the tip face alone.

Recut seats in head.
New washers.
New clamps and bolts.


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[Airthies]

Then once back together check injector trim codes are correct in PCM and do any updates then the injector and pump learns etc.

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