Please could I ask for helpful injector sealing advice. Before Christmas I discovered what could only be described as an acrid burning smell from within the engine area, I discovered a minor oil leak from the lower part of the engine near to the gearbox dripping onto the exhaust pipe but it was only very minor and occasional. On removing the air box I found that both the fuel pipes and the air box had been rubbing and were wet with diesel and thought "yep that could be down to poor running" but caught a glimpse of 3 of the injectors and what I can only describe as "tar" like in appearance.
After half a day of stripping down the upper part of rocker covers, and 1 week of chipping away black carbon, thinning it down I managed to clean up the injector orifices and sent off the diesel injector's to be tested by a local "bosch" diesel specialist.
Diesel Specialist informed me that the injectors were in okay and passed the tests they were subjected too, and supplied what he described as the correct washer already pre-greased onto the injector. I asked if these were now supposed to have the thicker copper washers available from Peugeot at a thickness of 1.9mm rather than the 1.5mm one but "Diesel Man" said no Bosch recommend that you use nothing but the 1.5mm already supplied.
As this was the second attempt at repairing and rectifying the "chug chug" noise I put in the injectors (after using a seat cutter to clean up the base of each orifice) and after getting everything nice and shiny put in the new plastic sleeves and injectors, using new clamp bolts and washers, tightened them up finger tight, reattached the fuel injector pipe union finger tight at both the Injector and common rail and then torqued it down to 20nm according to the Haynes manual and put on my replacement £135 fuel pipes across the top of rocker cover (really got upset having to spend that).
After that excitement, I began to slowing build up the rocker cover with new rocker cover gaskit, rebuilt the egr and pipe and upper part of the engine and eventually started it.
All appeared well and even after spraying a solution of soapy water around the base of injectors, no bubbles so I thought winner.
Today I went out for a drive, noticed a "whiff" of the acrid burning smell, got home and removed the air box only to find that cylinders 2 and 3, looked both to have a shiney black residue from around the lower bases, i.e they haven't as yet got above the level of the head casting for the injectors. Cylinders 1 and 4 appear to look okay and clear. I did try listening after original completion at Christmas with the "pipe method" but all cylinders sounded exactly the same.
How many times is it necessary to have to remove and replace these injector seals and should the thicker copper washers have been used? as I will now have to strip down the engine...again I wont have to disturb cylinder 1 and 4 as they aren't leaking or blowing by so could the thicker washers just be used on cylinder 2 and 3?
Has anyone else ever had the pleasure of stripping down the engine, cleaning it all up replacing the washers and finding the repair fails?
I would welcome your advice please, Garry