Thanks for the update, fingers crossed for you when you get that injector out
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Thanks for the update, fingers crossed for you when you get that injector out
once you've got the injector out, if its kissed the piston (you wont get it out easy without lotto winning luck or big tools), scope the injecotor bore, the crown of the piston and the injector for damage. If its 1-4 thats gone and you cant get the injector out you can get a slimline scope down the glowplug hole.
JC..... I wish you didn't say that but it makes a lot of sense...... sadly. I've got this feeling right at the moment that you're probably on the money there.Quote:
Originally Posted by justinc
What makes these things let go like that? I didn't think it was a common failure, but I'm guessing it happens enough.
4.5 months down the track and I've finally got this thing up and running again! :lol2:
Firstly a huge thanks to everyone for their help, especially the magnificent JC!
So a quick recap, not far from home, coming up the hill into Orange, with my foot buried to the floor the ol' girl lost power and let out a massive plume of black smoke from the back of the car! Pulled over to check it out. I was hoping it was a delaminated turbo hose, but wasn't sure. Got towed home again...
So with JC's wise words and encouragement the diagnostics began.
Turbo hose was not delaminated, oil in the turbo/intercooler pipe
Oil was all through the induction system
Oil syringed oil out of the intercooler - this was flooded
Turbo play was normal
oil on the dipstick was about 1 mile above the high tide line
Pretty convincing it was a leaking injector to have had the sump fill up.
With the induction system out already the tapper cover came off, now this is an area I try not to go!
Ignition on to pump the fuel and injector #2 was like a garden sprinkler spraying fuel into the head. I was pretty convinced now that it was leaking.
Rocker bar removed,
Injector harness removed
Injector clamp removed
Injector removed
Inspection showed no damage to injector, hopefully a good indication a piston hadn't let go
Injector copper washer R&R and injector O ring R&R
Cleaned the injector port
Reseated injector, clamp and reinstall Rocker bar with rockers.
Reinstall injector harness
Pressurise fuel system and injector no longer spraying fuel.
Tapper cover back on.
Drop engine oil, get another bucket and keep dropping more engine oil. There was so much oil coming out, there was no wonder the crankcase ventilation was pumping it into the induction system! Put new oil back in.
Next to clean the intercooler as oil was everywhere in the induction system
Blinkers out, trim off, grill out, horns out. radiator cover off, fan out, shroud out, intercooler hose off, release radiator clamp, release condensor clamps, spill coolant everywhere, remove intercooler, spill more coolant everywhere. Not as easy as it sounds for my first rodeo!
The intercooler was loaded with oil, drained this overnight. Now I understood why people were fitting Provents to catch this oil and keep the intercooler at max efficiency by not allowing it to become an oil trap and lose efficiency.
Reinstall intercooler and reassembly of seemingly half of the front of the car, fill up the coolant again!
Try to start, not start. Put battery on charger.
Try to start, cranked but no start, battery died again, battery on charger
Try to start, no start. Check RAVE. Ahhhh purge and pedal to the metal for start up. 3rd go, lucky!
Diesel smoke bomb goes off and shed filled with diesel fumes! Got gassed. Smoke clears, and exhaust runs clear. Very happy chappy!
Renew NRMA Roadside membership, renew insurance.
Test drive. My biggest worry apart from the engine is blowing intercooler hoses off. Full boost test drive on the driveway. All good. Hoses didn't move.
Test drive on the road, max rpm, max boost, hot engine, local hill, all good.
The engine so far seems like everything is working well, no weird smoke, no weird noises, power is normal, happy driver.
Gave it a wash, hooked up the trailer and took a picture because I was pumped the ol girl was up and raring to go again.
Still my favourite car! So many good times!
Great news Simon and thanks for the time for the detailed report of your findings and solution. So often we hear of the problems but nothing of the repairs/results.
That must have been quite a significent leak at injector #2. Did I read correct that you simply cleaned it all up and replaced it with the original copper washer and 'O' ring or did you renew all 5 copper washers and 'O' rings?
You're very very lucky you didn't suffer a 'runaway' event with so muck diesel in the sump and induction system.
You can now have a truly Happy Christmas!
Great news Simon. However I'm surprised that you didn't renew the other injector seals.
Good outcome.
Nice to see it up and running again.
Thanks Roger. I was so lucky that I didn't have a runaway, there was so much oil through the induction system, it was crazy. At the time JC said he had a runaway Td5 in his workshop. The other area that I think I was lucky was that the diluted oil didn't cause a failure in the turbo. I only touched the one injector where the O-ring and the copper washer replaced with new OE parts.Quote:
Originally Posted by Xtreme
So very happy, I've been driving it around today!
I only touched the one injector, I didn't like to push my luck with the rest but actually I wanted to get it all checked and all of them replaced when in for the next service and then they can do all of the pump adjustments etc. I'm sure if one has gone, the rest wont be far behind. The new copper washer measured to within 0.01mm I think it was of the old one so I didn't adjust anything, but I'd rather not do anything to the engine internals if someone else can do them!Quote:
Originally Posted by Graeme
Thanks, its so cool to be driving it again! I actually used your tips to remove the engine fan with the hub bolt removal and a full sized spanner rather than a thin engine fan type one.Quote:
Originally Posted by Tombie
Any chance of a link to this method?Quote:
Originally Posted by Slunnie
I've never heard of it before but it sounds like it could be handy to know if caught out on a trip without the specialist (hand made) tools.
TIA
Sure can:Quote:
Originally Posted by Xtreme
https://www.aulro.com/afvb/discovery...ml#post1537706
Basically, remove one of the 3 bolts on the hub (10mm head) and then you can use a full sized 36mm spanner, just tap it with a mallet and it eventually will release the fan nut.