Anzafin

Thanks for the info (DPF).

I think there is definitely something else broken in addition to the swirl flap(s). Possibly a twisted/jammed valve(s) and maybe the piston and the top of the cylinder are damaged. I'm afraid that the engine will need some repairing. At least you have to get it checked and search for damages. This will require the removal of the intake manifold and the cylinder head, exhaust manifold, turbo and other relative parts.

- Antti -

stevolution

okay lads, time for an update for my unwanted and unsavoury conundrum.....

a few weeks ago I drove from glasgow to durham after work to buy a forum member's spare inlet manifold. (newer style 2007 for instance)

My inlet manifold had an actual hole on the underside. It was a hole in one of the branches about 2 inches from where it connects to the head. The hole was almost big enough to fit a pinky in but not quite. It looked like something burst out of the hole, minute plastic shards aiming out the hole.

The swirl flap at the above branch was buckled looking and had 1 screw missing.

I can't remember exactly what injector/piston has the trouble, i just remember it being 1 away from the end (2 or 5)

2 or 3 of the other swirl flaps were a little bent looking but no screws missing.

After the manifold was replaced the car certainly ran better but still rough. There was no diesel mist at all but still an 'injectory noise' as i recognise it.

The mechanics have had a lot of other work to clear before I sprung this little gem onto them. Recently however, they've tried removing the injectors. They can get every injector apart from the most suspect injector. It just won't budge. They apparently know most of the tricks, coke etc. It is now booked into a diesel specialist to have the injector removed. They are busy and it will be 1st of May before they get round to this.

(i've seen the horror movies on youtube with people using crazy fulcrum planks of wood etc)

I'd like to mention at this point that there was infact a lot of carbon build up around the broken swirl flap 1/3-1/2cm of gungey carbon in places. (same swirl flap that has the hole in the branch)

Again to recap, since the problem arised, The car has covered approximately 10 miles, not sure if this could or could not relate to the carbon build up.

The mechanic also asked me when and why was the turbo replaced. He was thinking that perhaps the missing screw was responsible for the broken turbo.

I have spoken to the other mechanic who did the turbo. I'm not a mechanic so can only pass on what he said. He seems to be under the impression that the turbo was not broken because of a screw.

When the turbo went, i remember a weird noise but that's about it. quite tinny if i remember correctly.

So now we need to get this last injector out, then the mechanics can get the camera down there and inspect for further damage.


I hope i've managed to portray the problem to you guys okay so you can have a right good think about it and advise me well

cheers

Percy_991

Sorry to hear; not good. I've also experienced problems when my turbo blew and cat sucked in oil; both had to be replaced so do sympathize with your plight.

stevolution

Right guys, update time.

Managed to eventually get that last injector out, the washer was stuck also.

I took all the injectors to be tested. The injector which was completely stuck was dead. 3 injectors are fine, the other 2 injectors were failing at certain pressures (one worse than the other) but nothing major. The injector tester guy (argle diesels, East Kilbride) advised us to put replace one injector certainly and leave the worst 1 of the 2 nearer the front of the engine so it can be replaced easily.

Everything got put back together and it still wasn't running right.

A compression test showed there was no compression in 2 of the cylinders.

The head came off and there were 2 cylinders which had bent valves (sorry for vaguenes)

Eventually the valves got replaced, springs etc and everything got put back together (this was just last week)

The car sounded a wee bit rough last week. Not bad but just a wee bit lumpy. I don't know if it's my imagination but it seems it's starting to sound a little better

However, one sound that isn't particularly welcome was noticed when my girlfriend was slowly driving up the drive, there is a slight incline and without touching the gas and driving up the incline, the load was making, not so much of a ticking noise, more of a deeper 'toc tuc tuc tuc tuc'. It's a sound that I've heard lots of black cabs make. Girlfriend took it back to mechanic and he said he thinks it's the other injector, problem is she didn't demonstrate the noise, I would have preferred if she did that.

I'd love to think it was the injector.

One slight potential oversight on my behalf is the fact that I assumed that the 2nd and 3rd injector had been at what ever % effective before the car developed problems. Something i've not thought about is the fact that the injectors may have been slightly damaged due to incident itself.

The car has been a little smokey recently, might have seen some blue in there . However, I tailed my lady home from the gym tonight and I didn't seen any smoke. I did smell oil thought when she was parking tonight.

I realise that there can be some scoring in the chamber, yuck.

She's not put the sanny down, but it's seems certain the turbo is working just fine.

Economy hasn't changed at all either. 46mpg

By the way, a point to note.....When I was in Argyle Diesels (these guys get a really great name), he said all you need to do in future is disconnect the vaccum hose for swirl flaps. He said the problem is the swirl flaps try and push against carbon no matter what and that's what mangles the flaps then loosens the screws. He said if you disconnect the vacuum pipe the flaps stay open and he reckons you will never ever have a problem.

Thanks for reading

turboawd

what caused the valves to get bent?? could the swirl flap screw have done that? and the hole in your manifold..thats just weird.
would you have been better off to replace all the imjectors? or do they cost a small fortune?

how many miles on your car?

stevolution

injectors are quite pricey.
the whole is extra strange, really weird.
115,000 miles on the car
looks like screw may have done the damage, however, on this occasion it has not effected the turbo or cat.