2001 2ltr hdi 110 engine problem help please

[BEALEY]

i have bought a 406 hdi 110 wich had thrown a con rod. i have recently fitted a new engine. the engine runs fine but theres allot of white smoke wich is unburnt diesel it is not head gasket i have had it checked. also the engine starts to missfire when it gets warm. i have checked all the wireing to make sure that i havent plugged a sensor in wrong and i have checked the timming everything has been done correctly. i am a diesel mechanic but havent really worked on hdi's before and i am baffeled by this fault.

hope someone can help as i am out of idea's thanks (BEALEY)

[Doggy]

Hi Bealey & welcome

Sorry, can't really suggest any answers, but plenty of questions......

Does the EML go out when it starts? Does it stay out?
Is it just smokey on startup, or does it stay that way?
Is it running on all 4?
Done a compression test?
Do you know why it threw the conrod? (wondering about a possibly runaway).
Have you read the fault codes?
Does the temperature gauge work correctly?

[BEALEY]

thanks

the eml does go out. compression on all cylinders is fine temp gauge works fine it smokes all the time and even more when i rev the engine and starts missfireing when it gets warm.

i am not really sure why it threw a rod the old owner did say he was driveing down the motorway and it sounded like ihe had ran over a cats eye. when he did eventually pull over all the oil was missing and it was running on three cylinders and knocking quite badly hence conrod thrown but he said that the engine never smoked before and it dident when i went to look at it it ran fine but on three cylindres and knocking i havent had the codes read at the min thats going to be the next thing to do

one thing i remember is that when i started it the other day anti polution fault came up on the display but hasent shown up since would this cause my problem

[BEALEY]

may sound silly but i wonder if the engine timming is out 180 degreese on the crank would the hdi engine start up if i had timed it up wrong ?? because i have found out that my engine is fireing afther TDC hence the white smoke its just throwing diesel out of the exaust

[jasper5]

may sound silly but i wonder if the engine timming is out 180 degreese on the crank would the hdi engine start up if i had timed it up wrong ?? because i have found out that my engine is fireing afther TDC hence the white smoke its just throwing diesel out of the exaust

Did you recon the old engine or did you fit another engine?

How did you set the timing?

[BEALEY]

i fitted a new engine old engine was smashed to bits here is what shes doing got a vid: lvonO68XImU
http://www.youtube.com/watch?v=lvonO68XImU if it works lol i am useless with this lol it runs like it should but theres lots of unburnt diesel when you rev it up and it missfires when reving up its a strange fault any help would be appreciated

Edit by Welly: Link brought to life

[wasp]

Maybe egr valve? giving anti pollution light sometimes aswell..just a guess tho..
i think some early hdi's like mine had valve control module on bulkhead next to turbo boost control module (both black plastic valve things with wire and pipes &and look very similar 2 each other drivers side bulkhead) whereas modern ones! have a butterfly setup instead on the air intake pipe righthand side and level with top of rocker cover. my point is maybe the donor engines egr setup conflicts/differs from the original cars setup?
Good luck anyways
Dave

[wasp]

I just watched your vid link..maybe my therory was right.. i see two valves on your bulkhead,and looks like butterfly setup also! on intake but its hard to see.
other thoughts
..airleak in fuel lines around pump & fuel filter?
was the fuel system the same on old and new engines ie both Bosch or both siemens-
engine ecu will be either bosch or siemens also.....these all need to be correct.

Must be annoying cos its sounds healthy enough.

[lozz]

iwouid check the timing,

is it my ears or does it sound like the turbo is running on over boosting going off the vid
when irev mine like that itl boost and then the turbo will cut,

[Doggy]

If you've got the original ecu with a different engine, that could be your problem.

As wasp says, there were changes in the sensors and actuators along the way.

Another possibility is the injectors - not suggesting there's anything wrong with them, but I did read somewhere that they come with several different code letters, (A - C or something like that). If replacing an injector, it has to be the same code as the others. Changing all 4 to a different code is possible, but the ecu has to be re-configured to match.

I don't know this is the case - it's just a suggestion.

[steve_earwig]

It sounds to me like it's not firing on all cylinders when you rev it. I know if an injector fails the engine should stop but is it possible for one to be stuck open?

[Welly]

Did you re-fit the old Turbo? if so the Turbo could be knackered after it ran dry of oil.

The EGR is leaking there, it shouldn't be smoking like that but it wouldn't cause that amount of smoke out the back either.

[BEALEY]

thanks every1 the sensors/pump and common rail etc is all from the original car. i had checked the turbo before i re fitted the engine and it was fine looked new to be honnest also it does sound like its constantly boosting but i checked that 1st and its ok. i removed all the injectors the other day and 2 seem to be clean just sutted up with a bit of diesel round them. the other two have lots of diesel round them and carbon buildup i am going to get some1 out to read the ecu on thursday so hopefully that will bring something up thks again every1 any other ideas will be very helpfull. i will do another video tomorrow and try to give you a better idea of the problem its hard to explain in words lol i have a feeling that it could be the injectors at fault my self

thks again BEALEY

[BEALEY]

sorted the problem at long last it was the injectors it runs sweet now and she should be on road soon thks again for your help bealey