2012 2.2 RWD excessive pressure.

[womble171]

After some advice please?

Ive have just done the injector seals after excessive pressure and fault code pn injector 2. Before doing them. I done compression tests and they read 25, 9, 20 and 24. After doing the seals they read 25, 26, 18 and 14. I used Elring washers and seals, and cleaned all the seats up before installing. Still got excessive pressure though? Ive got a bit of smoke coming from the intake side manifold on 2nd from last pot, would this indicate cylinder or piston damage? I took the rocker cover off and cleaned that put, but didn't look too bad to be honest.



I was thinking of taking the head off to inspect further? Can you do the pistons without taking the engine out,? If not, are they easy enough to get out?

[womble171]

Attached some images,video for reference.

[metalworker0]

is that kg/cm2 or bar . i read that they are nearly the same

not a lot know that here .. we mostly work in PSI as standard

I had to do a conversion to psi to understand it

Diesel engine needs at least 300 psi to function properly .. that is 21.1kg/cm2

a good 2.2 would have 340 plus to be very good (23.9) with no more than 10 percent difference between cylinders

The difference between 14 and 25 is a long way beyond 10 percent

You need to take the head off

18 and 14 in two adjacent cylinders suggests head gasket has blown between them

with injectors out you'd be able to hear air escaping into the adjacent cylinder with a leak down test

Well that is my conclusion .. it's my best guess.. IF not ..it maybe that the engine bore or valves etc are worn out.

A head gasket can blow between cylinders without effecting coolant consumption or putting coolant in the oil .. but it may well have both .. and you have not found that yet .. because you have been looking at other things.

all the best.mark

[metalworker0]

Attached some images,video for reference.

when you carried out the compression test .. it would have sealed if you'd tightened it well enough .. although the seats show some tool chatter. i would have thought the compression test would be accurate .. as it's well below what the pressure the seats cope with, when engine running

others will give their opinion.

all the best.mark

[metalworker0]

its possible for head gasket to blow between the cylinders and into the crankcase ..

was video of it chuffing before or after the seats were cut.
its all guessing .. with this remote diagnoses, and you need other checks to be thorough .. leak down , boroscope, coolant pressure tester . .. what ever you do .. i think the heads going to be coming off .


the boroscope would let you see if you've had piston meltdown .. due to one or two of the injectors failing
wait for others to give their opinion .. you need more than one opinion!
all the best.mark

[womble171]

Thanks Mark.

I actually forgot to mention that it is losing coolant, but oil does not appear to be contaminated?
The pressure was there before the injectors were done, but the chuffing appears more visible on the camera as opposed to the naked eye. I will see if I have a video before I done the injector seals for the 2nd time.

I put it into a garage in May to initially get the seals done, but it looked like they had only done cylinder 1 amd 2, as 3 and especially 4 were stuck in. They also had the wrong size washer on cylinder 2.

[metalworker0]

As i just added
The boroscope would let you see if you've had piston meltdown .. due to one or two of the injectors failing... and unusually clean piston tops due to the water ingress ..you'd be able to see the injector spray pattern marks on the top of the piston and workout if all jets are firing equally.
Whilst borscoping you could have it under pressure of a coolant pressure tester and see water leaking into the cylinder ..
Have i covered everything? ..I don't know, I will probably think of more things later .

all the best.mark

[womble171]

Thanks for your input Mark. I will tey and pull the head off it the weekend and hopefully know what needs doing then.

[tranmx2]

The EGR cooler is attached to the bottom head and to the exhaust. The vacuum pump is attached to the cam shaft holder and the bottom head. Both are at the back of the engine. To get at one screw on the vacuum pump cover the EGR cooler needs to be removed. It is more work to take the engine out but it'll be a lot easier to access the engine when it is out of the vehicle. It seems you'll be doing some of the valve seats. From what Mark mentions there could be a head gasket leak.
The valve heads are very close to the head face - if you think you'll be skimming the head you may find you have more work than you want.
Could save yourself a lot of ache by fitting a reconditioned engine - cost about £3000.

[womble171]

Thanks for info mate. I’m trying to keep the cost down as much as possible as not much work doing at the moment, and it’s having a knock on effect with not being able to use the van. I actually have a spare engine that I got swapped a couple of years ago when it seized. I was contemplating stripping that down and refurbing it, then throwing it in? I’m using it for visual reference points at the minute.

[tranmx2]

Vids for contemplation and wet days.
https://www.youtube.com/watch?v=KB6yMch23xM
https://www.youtube.com/watch?v=L767i0D7gD0
There is another Salvage and rebuild vid but I've not found it.

Vacuum pp screws hold cover - bolts hold unit to upper and lower parts of head.
EGR cooler is bolted onto exhaust and to block and possibly the lower head.

Vacuum pp EGR cooler.png

[womble171]

Thankyou., Every bit of info that helps appreciated.