Howard1471

The problem, as I understand it, with this engine, is that it churns out a lot of muck. The EGR valve recirculates exhaust gases, complete with all the soot left over from the combustion. This builds up a residue in the manifold and EGR valve itself and gets in the oil. The sooty-oil clogs up the Turbo oil feed and pickup pipe which in turn starves the turbo of lubricant and when that fails, as a result, the whole thing gets well expensive. This is all compounded when the EGR valve, itself, gets stuck because its cloogged up and stuck open.

I'm advised that low soot/ash oils are a must and a regular oil change is very beneficial. My advice to anyone is get the Manifold and EGR valve cleaned out if it's never been done. Do an oil change every 3 months ( depending on use ) and check for injector leaks ( Hold your hand over each injector to see if there's exhaust puffing out ).

And most importantly, get someone who knows what they're doing, to do it all.

1. The original call out, remove injector, clean, fit new seal, reinstall, fuel prime, clear diagnostics codes and start, £50.00

2. Purchase reconditioned Injectors ( Unit Swap ) , 4 off @ £150.00  = £600.00

3. Replace all injectors, remove and clean exhaust manifold and EGR valve, reset ECU codes to Factory defaults ( someone in the past had tinkered ), reprime, start and test drive. £150.00

 

Total paid £800.00.

 

I've found a local Mechanic with a lot of diesel experience, with cars and commercial vehicles ( Vans etc ).  The costs are kep down by paying cash and not looking too closely at the figures on the invoices.   Suits me.

 

RAF258

Yes It's sorted, cost a few "bob" but it's sorted.   Read on.

I removed the engine cover to inspect the "sealant" I had been advised about.  The rightmost injector was puffing out exhaust like an old Mamod Steam engine. Obviously got a leaky injector seal. Consequently the black "sealant" turned out to be Carbon deposits from that leak. Reduced compression, poor ecomony etc etc. So much for the garage that did the service, how could they miss this lot?  I spent a couple of days patiently removing the Carbon, there was a lot.

I wanted to replace the seal but couldn't budge the injector. Got on to Yell.com and found a local mobile mechanic, he came and looked at it with his diagnostics computer and advised me that the injectors were all buggered and would need replacing before they failed completely ( Cheaper to service swap than replace ). It took him about 30 mins to remove the leaky injector, fit a new seal and put it back together. Re-primed and started.  He advised me that the Manifold would be full of S##t as would the EGR valve. This I'd read about. Not good for Turbo life. When he came back with the replacement injectors he cleaned out the aforementioned, fitted the new bits and it's now back on the road with no white smoke.

The lesson to be learned here is that despite how simple these things look in the Haynes Manual, it's far easier to get this sort of thing done by someone with the kit and the experience. Well worth paying for.

If the Injectors are down, replace them whilst you can swap for recon units. If they go altogether the cost is doubled.

OK, that would fit with something the garage said when they serviced the car a few weeks ago, some sealant on/around one of the injectors. Could a leak in that area cause this problem ?

Had my DPF removed 12 months+ ago. The [Ford] DPF is expected to last approx 60K miles.