2.2 CDi woes

[Crashy]

2.2 CDi engine fitted in a 2001 Sprinter.

Firstoff, it's my spare work van so if something gets broken, it's no big deal, plenty of time to work away at it and get it going.

My mechanic was changing injector seals, simple enough job, but when he was tightening down one of the clamps, one of the bolts sheared off. I'm not blaming him, was an easy thing to do. Read a few guides online, it was recommended that I bored out the upper part of the hole, fitted a helicoil and new bolt and clamp it down again.

Fantastic job. Worked well but have now covered approx. 1,000 miles and the put put put has started again. Any CDi people will know this is the time to sort it before the dreaded black death appears.

Where do I go from here? Is it time to look for a second hand head?

[Steve_D]

You are saying it is leaking but don't say what has happened to the helicoil repair. Has it broken?

Perhaps your mechanic was not prepared to tighten it quite as far as before and now it needs a tweek.

Steve

[C. Grimsley]

You will need to make sure the Black Death hasn't gotten into the hole causing the bolt not to be able to be fully tight (bottoming out), also if that's not the problem did you re cut the injector seat and use a new copper sealing washer, I know it's stating the obvious but I thought I would ask. Have you tried just tweaking it a bit more?

The standard m6 threaded bolts are a nightmare.

Carl