Thread: white smoke and runs on 4 cylinders when cold

Hello! i have assembled the engine and now i'm planning to adjust the injectors, but before i do that i have one question:

The manual says that i have to lock the camshaft in certain position before removal. i didn't do that (but it was in that position for removal), because i still have to rotate the camshaft to remove all of the injectors. Did i mess up?
is it possible that i damaged something on reassemlby when camshaft wasn't in that position?
I don't see how that could happen, but i'm really anxious and wanted to ask before i destroy something

You should lock the engine at TDC with a tool in the flywheel then you can lock the camshaft by placing another tool or a drill bit in a hole that is at TDC in the front of the cam. The cam sprocket has a range of adjustment so you should make sure that the cam is timed correctly. The procedure is in RAVE.

That way you know that the timing is correct.
Regards PhilipA

Originally Posted by PhilipA

You should lock the engine at TDC with a tool in the flywheel then you can lock the camshaft by placing another tool or a drill bit in a hole that is at TDC in the front of the cam. The cam sprocket has a range of adjustment so you should make sure that the cam is timed correctly. The procedure is in RAVE.

That way you know that the timing is correct.
Regards PhilipA

Yes, but since i wasn't doing enything with camshaft other than rotating, everything should be fine, am i right?
I know that this questions might seem stupid, but all of that engine stuff is really far from my comfort zone

edit: I worded my previous post poorly, i meant removal of the rocker shaft, not the camshaft!

edit2: I have to turn the screw untill the plunger bottoms out. that means, that it has to stop completly, right? some resistance is fine, since there is a spring?
Damn, i really regret not taking this car to some specialist

edit: I worded my previous post poorly, i meant removal of the rocker shaft, not the camshaft!

Ah! no wukkers then.
I pinned mine just to check that the timing was 100% and that the timing chain had not stretched as the cam timing can be adjusted at that time. I did the pinning just in case there was something in RAVE that missed a step or something.
AFAIK you should just turn the rocker adjustment down until it touches then back off..
Regards PhilipA

Originally Posted by Maciej

.

edit2: I have to turn the screw untill the plunger bottoms out. that means, that it has to stop completly, right? some resistance is fine, since there is a spring?
Damn, i really regret not taking this car to some specialist

As you wrote this .. not correct. No resistance at all and needs bump stop clearance.

Yeah, like Philip said screw the plunger thingie till it touched the lobe THEN BACK IT OFF BY ONE FULL TURN of the screw to set the clearance. It needs clearance shouldn't be touching.

RAVE also says that you should rotate engine a couple of times and then double check that none of the rocker screws touch the tops of the injector bump stops.
Note it's not like tappets which sometiems need some millimeter clearances, just the one full rotation backing off method on TD5 injectors.

Just to clear things up re: injector bump clearance
Get the camshaft lobe at the highest point on each injector , ( ie pushing the injector plunger down as far as it will go , then turn the screw down as far as it will go , then back off 1 turn .

Philip, even if Maciej has an excellent command of the English language , I think he might struggle with the word " wukkas "

I think he might struggle with the word " wukkas "

Probably more so with the full translation of "worries."
Regards PhilipA

Originally Posted by AK83

As you wrote this .. not correct. No resistance at all and needs bump stop clearance.

Yeah, like Philip said screw the plunger thingie till it touched the lobe THEN BACK IT OFF BY ONE FULL TURN of the screw to set the clearance. It needs clearance shouldn't be touching.

Well, now i'm even more lost, because when the camshaft lobe is at the highest point, the rocker touches both injector and a camshaft even when the adjustment screw is turned all the the way up. But i have found a TD5 specialist who will do it for me, let's just hope i didn't destroy anything by accident

Originally Posted by discorevy

Just to clear things up re: injector bump clearance
Get the camshaft lobe at the highest point on each injector , ( ie pushing the injector plunger down as far as it will go , then turn the screw down as far as it will go , then back off 1 turn .

Philip, even if Maciej has an excellent command of the English language , I think he might struggle with the word " wukkas "

Originally Posted by PhilipA

Probably more so with the full translation of "worries."
Regards PhilipA

This is how I tried to do it on one injector, at first there was a little bit of resistance (a really little bit) and i saw the plunger going down, and then there was a bit more resistance and i stopped as soon as i felt that, and then i decided that i have no clue what i'm doing and started looking for a specialist again
unfortunetly i have to wait a week for him, but at least I won't be so stressed

Thanks for explaining the word wukkas, i really do love australian slang! : D


And thank you all again for the replies, i am really grateful!