i replaced all 4 washers and seals on the injectors on my car 1.6tdci

was driving today perfect around the city and on the motorway.

went from city > motorway > City > Motorway, while on the motorway this time i put the foot down to get the engine working and clean out any crap using high revs,

over 3,500 revs and the get a knocking noise in rotation with the engine (tappet like noise) and when i take off i get black smoke, knocking noise is always there,

the noise is coming from around the injector area, but no leaking and no smoke from injectors.

what did i do and what do i do to fix it ?

Possible air leak did you put the injectors back in the order they came out if not will need recoding

I numbered them all and put them back in order.

I dont see anything loose.... no engine light on either

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Ive changed a couple of sets of injectors after a seal and washer change due to the injectors blowing (sound like a chuffing noise) could be problems with the injectors,

Might be worth sending them away to be inspected

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i know the chuffing noise you mean and this is different. more of a tappet noise this is. and black smoke on acceleration.

i was thinking they might have to be reprogrammed because they were cleaned out etc.

because theres nothing loose and everything is secure and no smoke leaking from any injector

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You could try re-setting the ECU so it has to "re-learn"

Also, its a good idea to give the car a service (air filter, fuel filter, oil&filter) if it has not been done very recently

refurbishing/ replacing the injectors could be expensive

Check for later calibration and possible recode. The injectors might not be recodable but you might be able to reset the learn values back to standard.

If that dont work then high chance it could be the injectors from my experience

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lads think it might be something dropped into the engine through the small rocker cover that was off....

not sure whats what

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hi lads,

just thought id update you on this.

what appears to have happened when i took off the oil filter housing to replace gaskets/seals a mechanic in a garage put silicon / gasket maker around it to stop it leaking.

fast forward to yesturday. a new mechanic did an investigation on the engine. top off head off, the loud noise was valves pushing air from the engine.

it appears (the only logical explanation) is that a peice of silicone/gasket maker broke off from the oil filter housing and blocked an oil channel in the engine thus damaging the head of the engine.

now it is possible to repair the head and recondition it but without finding what is blocked there is no point to do it.

cheers all for advice regarding injectors.

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