C5 2.2 Hdi - fault after fitting new Injectors

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KevMayer
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C5 2.2 Hdi - fault after fitting new Injectors

Post by KevMayer »

Hi,
I recently fitted some refurbished diesel injectors to my 2.2 HDI in my C5.
The engine started and ticked over nicely, but, when I took it for a drive, as soon as I pressed the accelerator pedal to move off there was a bang followed by a loud ticking/banging noise and lots of white smoke (I assume unburned fuel).

I've taken the 'new' injectors out and removed the inlet manifold. All the rockers look ok.

Of the 4 injectors 3 were dry and the 2nd from left was very wet.

Does anyone have any experience of this or any ideas what might be the problem?

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GiveMeABreak
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Re: C5 2.2 Hdi - fault after fitting new Injectors

Post by GiveMeABreak »

Apart from the specific injector issue you mentioned, were these the correct injectors and were they coded to the engine ECU?

KevMayer
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Re: C5 2.2 Hdi - fault after fitting new Injectors

Post by KevMayer »

Hi,
Yes, they were carefully selected and are definately the correct injectors.

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Paul-R
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Re: C5 2.2 Hdi - fault after fitting new Injectors

Post by Paul-R »

Were they coded in to the engine?

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Re: C5 2.2 Hdi - fault after fitting new Injectors

Post by KevMayer »

Hi,
The injectors don't need to be coded on this engine.

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Re: C5 2.2 Hdi - fault after fitting new Injectors

Post by KevMayer »

The engine is a 2002 4HX(DW12TED4) with a BOSCH injection system (apart from a Siemens fuel filter).

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GiveMeABreak
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Re: C5 2.2 Hdi - fault after fitting new Injectors

Post by GiveMeABreak »

No, but the injector mileage counter may need resetting in the injection ECU depending on the mileage if 3-4 injectors have been replaced. From 0 to 37.5k miles the counter needs setting to 0 KMs. From 37.5K to 50k miles the counter needs resetting to 80k Kilometers If the mileage is greater than 50k miles, then take no action on this front. Ditto for the MAF.

If the Engine ECU is changed then the Injector class must be checked.

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Re: C5 2.2 Hdi - fault after fitting new Injectors

Post by KevMayer »

Hi, and thanks for the replies so far. It's great to know there's lot's of knowledge and experience amongst the guys on this forum.

The engine has done just over 170,000 miles and all 4 injectors were replaced.

A friend of mine used to be a mechanic and, when I told him what had happened he immediately said he'd seen something like this before and in that case it turned out to be a miss placed seal in the top of one of the injectors. This blocked the fuel return to the 'leak off' pipes and resulted in the injector overfuelling into the cylinder. In his example, Rockers were broken on the affected cylinder.

So, I've checked my rockers and they all look good.

I'm next planning to remove the sump to see if there's damage to the big ends etc.

The banging when it happened was loud and sounded just like when I was a boy with my grandad when a big end bearing went on his mark 1 Cortina estate ( in about 1968).