C4 Engine & Box Out...

[Tonyl]

If the car is in economy mode it blocks radio. Locking/unlocking issues also often BSI reset related so I would repeat BSI process a few times as well as the ten second button push on the fob that is part of that. The errors on lights I had the same as front bumper/lights off for engine removal - I had also forgotten to plug the fog lights back in!! On mine, BSI reset sorted all on the third attempt. Eco Mode can be cleared by starting engine usually (a b* if you cannot start of course) and having a full battery or disabled through Diagbox in short term to allow functions that are needed.

[Doo]

If the car is in economy mode it blocks radio. Locking/unlocking issues also often BSI reset related so I would repeat BSI process a few times as well as the ten second button push on the fob that is part of that. The errors on lights I had the same as front bumper/lights off for engine removal - I had also forgotten to plug the fog lights back in!! On mine, BSI reset sorted all on the third attempt. Eco Mode can be cleared by starting engine usually (a b* if you cannot start of course) and having a full battery or disabled through Diagbox in short term to allow functions that are needed.

The engine wont start... I saw a drip, discovered a connector wasn't fully home on the filter. Push/click job done. That explains the poor pressure.

Still no start, found diesel on the cam cover... Discovered the injectors aren't seating properly! I dropped the head off at local engineering company for them to dress the injector seats and I can only guess they wen't a little further than "dressing" the seats. So tomorrow, I will mostly go asking for thicker copper washers (the ones that came with the kit looked fairly beefy, but clearly not quite enough). I wonder if it's worth anealing them

[Doo]

Got her fired up at last. Saw a post about DV6 engines needing a tow start and figured that ain't happening so I used some switch cleraner up the spout and she reluctantly fired. Once the lifters filled with oil & the diesel ran through the exhaust (obviously the injectors were firing but the valves were barely opening) and the white/grey smoke disipated, she ran. Idle is hopeless, but she revs cleanly and smoothly.

So I can't recall how to set the parameters on the injectors to allow the car to idle nice. Is it Maintenance or Repair? Then what?

Thanks all.

[Tonyl]

If the injectors haven’t been touched and go back in the same spot from which taken then should be ok?

[RichardW]

Did you replace the injectors? Should be an option to recode them under replacement parts somewhere. I was a bit confused about the cam chain timing, was your replacement the same as the original fitted?

[Doo]

Did you replace the injectors? Should be an option to recode them under replacement parts somewhere. I was a bit confused about the cam chain timing, was your replacement the same as the original fitted?

You haven't been following the progress chaps

Timing chain was 95 thousand miles in. It had started to wear through the plastic guide, so time to replace.

Broke the end off a glow plug, so head off. BUT, couldn't get the head off until injectors came out... But they wouldn't come out, so we tried ripping two of them out. In the end, we spun them out and plumped for two re-con units from Darwen Diesels (fantastic chaps to deal with ).

And that's us up to date

[Doo]

Well.... I went to programme the injectors using DB but one of the injectors has been scratched so I can't read the alphanumeric coding on top. I tried to scan the barcode, but it too is corrupted

I called Darwen Diesels to ask if they had a record of the codes, but I was told to simply run the engine for around fifteen miles so the ECU can learn and adjust. Which makes sense I suppose, but I wanted to play with the computer

First though, I had a friends Peugeot 308 for a front spring change. Crumbs, I had to pull the wiper motor out of that side (they have two front wiper motors....who knew) in order to fit the bar to undo the strut top nut. Whomever previously changed the nut had partially rounded off the edges so it was lippy bitey time But I got there. Then discovered my Sealey Hydraulic Spring Compressor is not staying locked So it was a case of pump, try to steady the strut, pump, install the bearing, pump, install the washer, pump, twist the nut, pump, use the gun for ugga dugga's to get it on before the pressure built up I got it almost all the way, but ended up using the 21mm ring spanner and a torx bit in the 3/8 ratchet to tighten it up. So now, I have to figure where it's drawing air I checked all the usual suspects, so I'm guessing a seal rebuild kit is next order...

Anyway, back to the C4. I installed new track control arms & track rod ends, but the wheels are like Marty Feldmans eyes, east and west So I now need to set it up as best I can before taking it to my mate who does laser tracking. He'll be delighted that the nut isn't rusted rotten because there is nothing worse than trying to undo a seized solid track rod end

Other than that, the engine starts 1st revolution and revs freely. So I'll take her for her maiden voyage, then drain the oil & replace it with the new filter. The price of oil is going to go nuts so I bought 2yrs supply recently. But I filled the engine with 15yr old new GTX as I wanted to flush out any crud left from the rebuild. Couldn't be spending £50 on oil just to drain it after a few miles

So that's where we're at for now. Other stuff is keeping me away from the car, but it's refreshing to get back to it knowing it starts and runs.

[Huskyxantia]

Well, trying to find a valve spring compressor small enough to fit this head proved to be somewhat difficult unless I wanted to part with around £130 or so

So I got the welder out, grinder loaded with cutting disc, a tub of nuts, bolts & washers and some scrap bits of metal and made my own.

Valves out and ready to be lapped. Cleaning the bits of carbon, lap the valves, then change the seals and hopefully....300 years later (since I started this bloomin job) start the rebuild

Photo's later....

Love making my own tools

Copywrite this as your own your be worth a few quid

[Doo]

Well, trying to find a valve spring compressor small enough to fit this head proved to be somewhat difficult unless I wanted to part with around £130 or so

So I got the welder out, grinder loaded with cutting disc, a tub of nuts, bolts & washers and some scrap bits of metal and made my own.

Valves out and ready to be lapped. Cleaning the bits of carbon, lap the valves, then change the seals and hopefully....300 years later (since I started this bloomin job) start the rebuild

Photo's later....

Love making my own tools

Copywrite this as your own your be worth a few quid

That's not my one. That picture belongs to another member....

This is my one:

[img]

[Huskyxantia]

Thats a serious bit of kit !its amazing what a bit of rust can do to them injector sleeves. I was lucky , slide hammer plenty of welly they came out , did mine last year , its a big job , your showing it whos boss.

[Doo]

Thats a serious bit of kit !its amazing what a bit of rust can do to them injector sleeves. I was lucky , slide hammer plenty of welly they came out , did mine last year , its a big job , your showing it whos boss.

I had the engine & box hanging on the crane from one injector... The slide hammer was in between, but made NO difference!!

We ended up spinning them out (unscrewing them from the nozzle cap nut) and drilling out the cap nut from the head. Worra mare.... That's really why the job took so long. We soaked the nuts forever with all manner of (non working) various fluids. Some days, you just have to take life by the plums and shake, squeeze & swear your way around.

Anyway, there is one (original) injector not playing the game, so I suspect it's going to be replaced. It's weeping diesel and that is not a good thing

But, seeing as how I have never built a diesel engine before (I have lifted them out and dropped them in, but NEVER dealt with injectors and the like), I am chuffed with the outcome. The fact it starts & drives having been in a hundred bits on at least seven different places around the garage and the back of the car, I am pleasantly pleased with the outcome. But not too much as an engine is an engine at the end of the day. I have carried out repairs on many engines, gearboxes and the various bits in between as well as stripping brakes & getting them back to not only working condition, but perfect working condition considering they were a pile of rust not long before...

At the end of the day, everything is repairable as long as you either throw money at it or spend some time understanding it and being able to strip it and put it back together as good as or better than before. I like doing brakes. Old or modern, brakes are the kingpin of the car and they MUST work EVERY time. No matter what

Anyway. back on track. I might need to purchase a new injector.

Bloomin cars

[Huskyxantia]

You need a youtube channel your do great on there .
Can't beat a good old fashioned tinkering as for brakes your so right there . Many moons ago i went to look at a mk4 escort young lad car, test drove it 400 yards brakes all scoring like mad .. no sell no buy..

[Doo]

Hi all, well....the saga of the engine endeth with the installation of a replacement injector from Darwen Diesels

I finally managed to get a minute or so to install the new injector and the engine once again sounds as it did before.

I covered each injector with a coating of silicone grease before installing. That is to say, the part that goes into the injector sleeve. Reason being, I do NOT want to face the drama of fighting to remove them again. I want a simple case of undoing the various nuts, bolts, plugs and leak off pipes without a fuss.

I took the car for a run (around 4 miles or so) and the only worry was around 200mtrs from home, a plume of white smoke after I planted the foot. However, I think the exhaust reached optimum temperature and it purged the remaining fuel from the DPF after the unburned carry on from the dodgy injector. After that, it performed beautifully. Tomorrow, we're taking her for a longer run (hopefully around 15+ miles) and carry out some errands afterwards.

Then, she'll be treated to a full oil & filter change as the oil I put in was purely to clean the system after the rebuild. It is new old stock of Castrol GTX which was too good to throw away, but not good enough to last a full service life of modern diesel engines.

I would like to thank all who participated in the help to get this car backup and running and I would also like to find the time to make a page of how I went about the various trials & tribulations of the journey. I'm not new to engine rebuilds, but this is my first diesel complete build & it was a journey I am delighted I took. It was all possible with the help from those of you who took a moment to respond. Thank you.

Yours always thankful,

Doo

[MattBLancs]

A good job done well, glad to hear is running well

I used "ceramic brake grease" on the injector bodies - am sure recommendation came from (googling and) a Mercedes forum where they must have similar steel injector in aluminium tube corrosion issues.

Some of the same on the body of the glow plugs too, try to minimise the chance of shearing those in future.

Matt