Warning to all who have a Td5 head skimmed...

[Sitec]

Yes, it works well... At 205000 kms the coolant disapeared, off with the head to find powderised plastic dowels and a slipped head. One skim later, new bolts, dowels (metal), gaskets etc etc and we're runnin on all 5 again with lots more power... (last owner had been in there.. silicon everywhere and timing was out) anyhow, 200km later and we have a misfire..... After a filter change and no improvement, I pull the little gauze filter out of the head to find it full of alli shavings! Not a happy bunny. Seems the machine shop didn't clean it out properly... After runnin it without the rocker cover, and pulling each injector lead off one by one it seems No 3 is at fault. Any one got an injector to suit a 99 Fender 130??? If not, sorry guys but it's getting the Nissan 6 treatment. Should have stuck to a Tdi.

[p38arover]

Shouldn't you have checked it before refitting it?

[big guy]

Bump!

[Scouse]

Bump!After 1 minute?

[Sitec]

It was checked, double checked, and blown out again! Nothing came out. Should have been plugged b4 machining as was requested!

[Psimpson7]

Did you or the head place rebuild it?

If the filter was clean when the engine was put back together, it would be very unlikely to get swarf in it in use. The captive side of the filter is on the fuel inlet side, not the head drillings side, so any swarf would have to come out of the head via the fuel return, through the pressure regulator, then through the fuel cooler, back through the fuel lines to the second filtered stage of the fuel filter, and then go back around to the engine.

I think I do have a couple of spare injectors that would suit a <01 td5.

[Sitec]

Would be very interested in the injectors. Mine have the 5 didget code on top with one random number below and to the right. The injector at fault is no 3 which reads 'LNLLA' and '4'. I've also since learnt that the fuel hoses were connected backwards... When I removed the head, I left these connected and removed the fuel block as one (quicker and assumed they were right.. not so). The original gauze was in bits. When the head came back from being skimmed I blew it all out to make sure all was well and clean and fitted a new gauze (not cheap!!). When the misfire arrived last nite, I changed the fuel filter first and then checked the gauze filter. This is when I learnt that the fuel lines were backwards as I found several alli shavings head side of the gauze. That has since been rectified. It bled easily this time to, which it didn't after the rebuild. Don't know how to contact you on here without upsetting someone (seem to have a habit of doing that) so let me know how to get in touch and I'll give you a call. Thanks. Simon.

[p38arover]

Don't know how to contact you on here without upsetting someone (seem to have a habit of doing that) so let me know how to get in touch and I'll give you a call. Thanks. Simon.

Haven't you heard of sending PMs (Private Messages) on the forum?

[alien]

Haven't you heard of sending PMs (Private Messages) on the forum?
When I joined I could only just drive the computer;)
Didn't know what a post or thread was, let alone a PM:D

[Psimpson7]

Hi Simon,

Just got your PM.

As you probaby know swapping out injectors is slightly more complicated that 'plug and play'

The injectors are coded to the ecu. Its a very easy job to swap the codes, but it does require the use of a diagnostics tool.

Would you have someone local who can do it for you? It may be worth getting someone to check that the codes are correct for the injector locations as if they have been put back in the wrong order that may be the cause of the issue. (and actually check for specific logged injector errors)

I will have a look in my garage in the morning and let you know what I have tommorow.

Rgds
Peter

[justinc]

When rebuilding an engine, or refitting a head to an engine, ANY engine, the galleries must always be checked and blown out thoroughly. The onus is on the mechanic NOT the machine shop to do this. Plugging the head ports etc is difficult and dangerous if whatever they use ends up in the cutter during machining.

We always do this, the machinist usually blows out obvious swarf etc but it has always been drilled into me to prepare the head for fitting in this way, regardless. Never rely on someone else to do it.

The injector issue may or may not be caused directly by this, the gauze filter is there to prevent ingress of particles.

Hope you get it sorted, Pete ( Psimpson7) wil steer you straight, he has quite a bit of Td5/ head experience.

JC

[Sitec]

Hello again all.
Believe me, I did blow the head out many times at all angles to make sure it was all clean. Been here before with Iveco Tector Euro 4 Engines. It's bad enough that we have to comunicate using these things called computers let alone have our pride and joy controlled by them, and yes Ron I am a computer novice... We can't all be a whiz at everything!
Have found a second hand injector locally and am going to see what happens with it fitted (yup I know I'll have to get the vehicle plugged in to set it up properly but I was not happy driving to Adelaide on 4 pots).
Watch this space... I've certainly learn't a lot... Still leaning toward a nice big jap 6 td (my old 101 used to fly with 6 litres and turbo!!) but the Td5's got one more chance!

Thanks all for the advice!!

[Blknight.aus]

dont just blow the galleries out with air... Flush them with the medium thats going to be going through them at at least the pressure that they are intended to have in them and at the same if not higher flow rate.

If you ever get the chance or an invite goto a machine shop with a good (200x minimum) microscope and ask to sample some swarf from a job being cut and then a look at the surface the swarf came from.

Ally tends to cut up with lots of little "spikes" that allow it to hook into things like velcro. This is more prevalent of high speed full depth cutting doubly so if the cutting tips shape or sharpness isnt great.

Dont panic about the injector code for the initial diagnostics of the rough running donk, the injector code just allows for fine tuning.

[Sitec]

New (secondhand) injector in, 2 3min key primes later and it started instantly on 5! No rough running, no audiable sound differences, no orange light, no smoke and bags of power! So now comes the trust earning bit... 200kms, 1000kms? Thanks all. I've certainly learnt a lot about Td5's!!:)