Injector Replaced (Car now stalls and smokes)
Discussion
Hi folks,
Looking for some advice after replacing an injector. Had rocker cover off, everything cleaned up, replacement injector installed.
Have reassembled twice (replaced seals and copper o rings twice) and I still have the same issue.
Car starts. Revs can't get above 1500. Engine often stalls within 20 seconds. Sometimes it stays running. Not enough power to get it moving. No fault codes.
When I remove injectors, they are coated black. I'm fairly certain there is a fuel leak underneath the car too. Looks like it's near the back, as it's wet underneath.
Tried using water (mist) to detect if there is a vacuum leak. Couldn't find anything.
Just looking for some advice on what to try next?
Mega frustrating, as I am certain that the injectors are installed correctly.
I've attached some pics that may help. Any help gratefully received! Even a few pointers on things to try next.
The car is a Hyundai i40 2012 1.7CRDI.
Many thanks,
Joe.![](https://forums-images.pistonheads.com/524633/202605105461941?resize=720[/img]</a> <a href="https://forums-images.pistonheads.com/524633/202605105468946" Target="_blank" >[img]https://forums-images.pistonheads.com/524633/202605105468946?resize=720[/img]</a> <a href="https://forums-images.pistonheads.com/524633/202605105470412" Target="_blank" >[img]https://forums-images.pistonheads.com/524633/202605105470412?resize=720[/img]</a> <a href="https://forums-images.pistonheads.com/524633/202605105472888" Target="_blank" >[img]https://forums-images.pistonheads.com/524633/202605105472888?resize=720[/img]</a> <a href="https://forums-images.pistonheads.com/524633/202605105479333" Target="_blank" >[img]https://forums-images.pistonheads.com/524633/202605105479333?resize=160)
Looking for some advice after replacing an injector. Had rocker cover off, everything cleaned up, replacement injector installed.
Have reassembled twice (replaced seals and copper o rings twice) and I still have the same issue.
Car starts. Revs can't get above 1500. Engine often stalls within 20 seconds. Sometimes it stays running. Not enough power to get it moving. No fault codes.
When I remove injectors, they are coated black. I'm fairly certain there is a fuel leak underneath the car too. Looks like it's near the back, as it's wet underneath.
Tried using water (mist) to detect if there is a vacuum leak. Couldn't find anything.
Just looking for some advice on what to try next?
Mega frustrating, as I am certain that the injectors are installed correctly.
I've attached some pics that may help. Any help gratefully received! Even a few pointers on things to try next.
The car is a Hyundai i40 2012 1.7CRDI.
Many thanks,
Joe.
Edited by Joeninho on Sunday 10th May 15:16
Edited by Joeninho on Sunday 10th May 15:20
If that's diesel & black gunge all over the body of the injector I'd say that the copper rings aren't sealing & you have a serious blowby issue forcing unburnt & partially burnt diesel past the copper seals.
Known as 'the black death' in Mercedes diesels when their copper seals fail.
Are the copper rings new, genuine parts or A.N.Other from ebay or elsewhere?
Are the seats in the head thoroughly clean & undamaged?
Known as 'the black death' in Mercedes diesels when their copper seals fail.
Are the copper rings new, genuine parts or A.N.Other from ebay or elsewhere?
Are the seats in the head thoroughly clean & undamaged?
The copper rings are new - Bosch. Replaced them twice now. Cleaned the injector wells (carefully) with a screwdriver and rag before reassembling yesterday.
I put a little bit of silicon grease on them to hold them on the injector, although I can't be certain that they are sealing properly. Found a busted up copper washer in one of the injector wells yesterday. Not one from when I've been working on it, as they are all accounted for.
I put a little bit of silicon grease on them to hold them on the injector, although I can't be certain that they are sealing properly. Found a busted up copper washer in one of the injector wells yesterday. Not one from when I've been working on it, as they are all accounted for.
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