possible injector at fault????

[winterheating]

125 2.0 tdci
driving along normal speed then van felt like handbrake had been applied, noticed loads of smoke behind me, slowed right down then noticed a rattle like a rocker had broke come of dual carriage way and it was still running, turned it off to open bonnet, loads of oil had come out the breather pipe, (cos i don't have it connected) cranked it over again and sounded like there was no compression at all glow plug light was flashing. got a tow home .
then as soon as i stopped checked the pas pump cam pulley was turning with engine, and it fired straight up but was missing.
stripped it down and this is what i found.

looks like somethings popped with that tar looking spray from cylinder 3.



don't laugh at my home made injector socket.



you can see where the injectors been removed, it looks like a dried prune next to the hole.



Not avery good pic but you can just about see the injector seal is carboned up and past it where it shouldn't be. and you can see the carbon lumps i removed, on rocker cover



it started raining heavy so couldn't do anything else, has this just all of a sudden let more pressure out and oil into cylinder, and why the loud tapping
should i just be able to clean it all up and reseal injector and it be fine
i was thinking the knock sensor picked up the tapping and cut the fuel when i restarted? which made it sound like no compression?

[coconut]

Was the injector loose (im guessing not or you would have said)

It is normal for the tips to be carboned up on the shafts up to the copper seals

Is there any damage to the inside of the rocker cover

Is this just a bit of tissue or is it something else


and is there a seal on the end of the injector (where the arrow is and what are the 2 lumps on top of the rocker cover (by the other arrow)

[winterheating]

them lumps on rocker cover are bits from the lump in first pic. picked it up and it fell apart, its carbon chunks mixed with oil, looked like its been building up over time. and other bits the same are splattered all over
the rocker seems ok but havn't cleaned it of yet.
the pic of the injector isn't very good i'll try and take another one tomorrow. it looks like the carbon has been passing the seal as theres marks on and past the hexagonal part after seal.
the injector was quite stiff for the first 4 turns out.
i just hope the head isn't cracked, or could the seal be passing from the internal part thats tight to the injector tip

[winterheating]

tried to start it today glowplug light flashed and instrument cluster says DTC 9359
what does that code mean?

[MrMPuk]

Low battery code.

[transitgeoff]

i think this conversion is always gonna be agg

[winterheating]

low battery thats ok then, thats why the glowplug light started to flash after a few times of cranking.

took some other pictures of the injector before i puit it back in but they didn't turn out right, at the top of injector just below the power plug connection there was carbon build up, at the base of injector threads there was signs of carbon build up, the injector itself was fused to the injector screw with the carbon so looks like i didn't tighten the injector fully

Geoff its been fine except for slight lack of power, so hopefully with the injector in correct it should be spot on.

but still going to put a 175ps engine in, have got hooked to the buzz off killing other vehicles on the road with a van

[winterheating]

tried to start it today, now joy so took fuel pipes from pump end off and they were dry, put clear hose on large pipe(flow ) into can of diesel and another from return. cranked it over with injectors cracked open, seem to suck diesel out of can and loads of air and froth coming down return. then seemed to stop so put flow back onto pump pipe, and used the priming pump, went hard but nothing comes out of return.
took filter off that was empty filled it up. put a vacumm pump on return and just pulling air through no diesel
decided to tow it, after 20 minutes of towing it started to run but loads of smoke with the throttle. towed a bit more and got it ticking over but still missing. just cuts out if you give it throttle with smoke.
looks like i'll have to get the injector checked and check the compression. what should compression be

[coconut]

I presume you had the injector programmed (or was it the original one sorry my mind aint working right tonight )

Compressions are around 28 bar for a 2.4 so a 2.0 would be around that as well I would have thought

[winterheating]

have had the injectors coded when first changed the engine which didn't make much if any difference that was 8k ago.

got it running straight away with a tow and will rev and idle but still misses and smokes.

then noticed white smoke pouring out of breather hose

took rocker off put pipes and cables back onto injectors cranked it over smoke seemed to be coming from crank.
noticed when one of bolt holes or locking hole on inlet cam was at 12oclock and exhaust cam was between 1 and 12 oclock
checked compression, even though my gauge only goes to 20bar 3 and 4 cylinder went straight to 19 bar 1 and 2 went to 12bar after a while of cranking gauge went up to 19bar on 1 and 2 but also on no.2 static pressure dropped and didn't on 3 and 4

so looks like i'll have to take head off any suggestions before i do this

also when i first fitted engine to inlet off just to have alook and all was almost spotless clean no soot, since then have had egr blanked and rocker breather not going into intake. today there was quite a build up off soot and lumps on intake ports, does this indicate that timing is slightly out?

[coconut]

The locking holes should be at 6'o' clock for the cams

Just a thought, 1 of the rocker shafts aint snapped are they or the bolts lifted slightly

[winterheating]

i havn't had the engine cover off yet just could see the holes at top but should the inlet and exhaust pulley be the same all the time

didn't think to check the bolts, suppose that would explain the the timing slightly out if the cam shaft has been lifting slightly

[coconut]

Ive looked at loads and though the timing was out but when timed up with pins they were spot on, I think its one of those optical illusion tricks

[winterheating]

suppose it doesn't take much to check timing is it twoo 7mm bits in cam shafts and 13mm in cps hole

i'm thinking the slightly leaking injector hasn't had anything to do with this problem.

just thought since engine been fitted i have always had slight bit of oil seeping from filler collecting on plastic tab below cap wasn't spillage as i kept wiping it clean wasn't the cap oring as i changed that. could this have been slight back pressure

[coconut]

Not to sure on the size of the flywheel pin, but it will have to be a tight fit into the CKP bracket and its 6mm in the cams

Generally if the engine is breathing heavy the 1st place to leak is the FIP access cover, never seen the filler leak before