CS 1.6d engine problems

[steviedee]

I have recently bought a T25 with the 1.6D (CS) engine. It is very low on power and blowing blue smoke.

Numbering the injectors 1 - 4 from gearbox end, I have tested the injectors with engine running by slackening the feed pipe in turn with these results:

Injector 1 - no change to engine running
2 - engine runs lumpy
3 - engine runs lumpy
4 - no change

I removed injectors 1 and 4 . 1 was very carbonated , 4 less so. Both cleaned and replaced and above test ran again
but with no change to the above results.

Anyone know what the problem could be?
Timing?
Could it be lack of compression in 1 and 4 (Any way of checking without a compression tester?)
Any other ideas??

[colinthefox]

Ok, no-one else replying so I'll have a go, based on my original clapped out CS.

Blue smoke is burning lube oil. That's worn piston rings or worn bores, or worn valve guides. Worn rings also produce lack of compression and blowby, which blows oil back into the air inlet via the engine breather.

Other problems resulting in lack of power and rough running could be cracked cylinder head producing low compression. Heads tend to crack between the valve seats, which is not much of a problem till they go right through to the inlet/exhaust ports. These cracks also produce sinking valve seats, which result in zero valve clearances. Symptoms of zero valve clearances are................starts OK and runs smooth for a few seconds till the valve stems heat up, then it's down to firing on 3 or 2 cylinders for several minutes till the head heats up, then it's back to all 4 again.

Could also be bad injector spray pattern, but this may result in black smoke, not blue. Remove injectors and have them tested by your local diesel injection specialist.

So.......a course of action starting with the most cost effective:-

1. Get injectors tested and adjusted.
2. Whilst you're there, get them to do a compression test. You could also try disconnecting the black wire from the injection pump (turning off the fuel) and cranking the engine. Listen for wheezing noises, uneven cranking, but no guarantee of success with this method.
3. Otherwise it's "off with its head" and look for head cracks, valve guides, and piston ring problems I'm afraid.

If the engine has done substantial miles it may very well be clapped out.

But wait and see if anyone else has any bright ideas.

If all eIse fails, I have a good 20K miles CS here if you're interested.

[mr strong]

Sounds like could be the timing is lightly off,
Mine has the same issues exactly.

Im changing the timing belt (as its not in my sketchy service history) and will see if that works before splashing on a new cylinder head, or piston rings etc.
If it revs up cleanly from idle its probably not your injectors either. ( Again cos Ive been thorough this) you could try an injector cleaner as a first off.
It might work.

Above all dont panic,

[kit]

Put in your profile where you live, lots of us have odd bits of CS engines lying around.

[steviedee]

I've checked the timing and it does appear to be slightly off.
With the flywheel / clutchplate centrered on its marker, the notch on my injector pump pulley is about half a tooth off alignment with the marks on the bracket (its a bosch),but the locking pin hole is centered. So naturally if I align the pulley marks, I can't lock the pulley (?????).
Also with the TDC mark lined up on the flywheel, the camshaft locking plate is not level.
I understand how to align the camshaft but its getting the injector pulley to line up thats giving me the headache.