Berlingo Starting Probs

[Bromptonaut]

1.9 IDI (DW8B/WJY series) motor.

In practical terms it comprises the cylinders/bottom end of an HDi with head, injectors and injection/timing pump of the XUD. As a late model this one has an electronic link from the cam end injector to the timing/injector pump to meet then current emissions regs. Pump etc is Lucas brand. We’ve owned it from new.

Now on 140k miles and other than a clutch that failed down route in Shropshire at 100k and alternator that did same 6 months later in Sheffield it’s done 140k faultless miles. Always started at first turn of key and immediately idled smoothly.

Three weeks ago it went to my normally reliable and trustworthy Cit specialist for major service. Cambelt was replaced as well as fuel and air filters.

Since it came back it’s been ‘odd’ starting. Slightly hesitant even when warm. From cold it’s decidedly rough, misfiring for 5-15 seconds accompanied by grey smoke and smell of incompletely burned diesel. Once running though it’s fine and pulling like a train as usual. Trips to Liverpool and Leicester return normal fuel consumption and other performance.

If it had displayed the symptom spontaneously I’d have said glow plugs not right or, if not, air in fuel. Plugs were tested and pronounced OK for circuit, resistance and timing. Observation on start up showed small air bubbles passing down line filter to pump in second after start but not necessarily coincident with roughness.

It’s been back to garage three times and after a ‘no fault found’ diagnosis *2 it was kept overnight with fuel filter fitted at service being adjudged faulty and replaced.

On cold start this morning it was still as rough as a Badger’s backside for 10 secs with grey smoke etc

Ideas for cause and where do I go next please.

[Lighty]

If glow plugs are fine, then valve clearances are the next step, the valves receed into the seats and the clearance gets less with mileage, eventually causing one or more valve to remain slightly open. 140,000 is bang on the mileage this tends to occur.