1.6TD smoky on start up.

[geordie skydiver]

My mates 1.6TD is a bit smoky on start up, kinda black/gray smoke that smells of diesel.

For the first ten minutes or so it blows a puff of smoke out at each gear change, then once it's up to normal running temperature the smoke disappears.

I'm thinking it's something to do with the injector pump, but I really don't have much experience when it comes to diesels.

Its recently had the head gasket and timing belt done, and the turbo was new in April. Other than the smoke it runs really well, 65mph, good on fuel, temp stays rock steady right in the middle of the gauge. Not loosing any oil or water.

Any thoughts?

[peasant]

Well ..a "bit of smoke" is quite normal.

Unless it's big, suffocating plumes I wouldn't do anything.

Just make sure that the head was/is re-torqued after the headgasket change and about 500 miles.

Next time round your friend is near someone who KNOWS what they're doing, he might want to get the valve clearances and pump settings checked and adjusted, if necessary.

[HarryMann]

Its recently had the head gasket and timing belt done, and the turbo was new in April.

Funny, 'cos that sounds like turbo seals... is that 'new, new' or 'new, 2nd hand' ???

I think he should check the oil level and dipstick calibration... as another reason could be oil level too high, they're very sensitive to that.

Change oil (4.5 litres exactly if no oil additional cooler)and re-new filter (regularly with a TD) and after starting up and waiting for oil light to go off, let drain back for 5 or 10 minutes, then check dispstick reading on level ground... use that level for top-ups.

[tonytone]

hellooo, well I had my 1.6TD fitted with a vege engine that i bought from them with new injector and plugs. The engine was all set up and ready to go when supplied. Guess what.......it smokes when under heavy load such as climbing big kerbs and steep hills, especially if you give it more throttle. I guess in this instance youre just chucking in but not burning fuel..

I Had the injector pump timing done recently to get it spot on and it still likes the occasional smoke. So there y go, Id expect it to smoke a bit here and there under normal use.

[HarryMann]

They do Tony,

The Injection Pump can sometimes be tailored a bit for that, if you don't like it. If it has the full Vacuum LDA unit, with spring and starwheel in it, and a Boost Pin that can be turned to change the extra fuel/boost ratio.

With that LDA unit, you should be able to tune out that occasional overfuelling. Few are really clean though, and my 1.9 isn't. I guessed all the settings when rebuilding the pump top, haven't changed them since and it does what I imagine yours does... only smoke badly when you're asking far too much of it, before the turbo has really begun to move much air.

and it should always pass the MOT like that. So I imagine they can be setup to run almost clean when all is new, or in good fettle. Particularly the turbo.

It's normal for performance to keep fuelling it on the main screw until the smoke or EGT starts to worry you, they keep going faster even after that

You want to be seeing maybe 10~11 psi boost, 12~14 with an intercooler for perky performance

[geordie skydiver]

Can the turbo seals be changed quite easily?

Its gotten much worse, and smokes all the time now. Oil everywhere too.

[HarryMann]

No... they can be serviced but generally this is a turbo refurber job, due skills, parts and rebalancing. Have done it, some documented in Wiki, but generally they are non-DIY-serviceable item...

[geordie skydiver]

Ok, I've finally got time to whip the turbo off for my friend and get it away to be refurbed.

Is there anyone on the forum that does this, and how much is it likely to cost?

Thanks.

[Ye Olde Syncrospares]

check to see if the crankcase breather is blocked,thatll make it smoke,check the pump timing thatll make it smoke,check the glow plugs are all glowing and the coldstart is working thatll make it smoke,check the valve clearances if its not burning diesel just sending it out the exhaust port guess what,cj.

[HarryMann]

No. 1 is air-filter cleanliness, or rather if blocked won't help at all, at all..

£350~£400 for the top guys, full refurb but

could try this guy, Blackpool, much cheaper than most, prob. xtra to re-balance shaft dynamically..

http://www.turborepairs.com/

Orientation of the exhaust section to the main central bearing housing is critical (for oil feed inlet pipe), so photo it before going and check its right before refitting as not easy to spin them in situ

Do all the other things too before refitting...