Walked in Sunday morning knowing what I needed to do; set the car up on the ramp as if I was doing the cambelt again so I could remove the engine mounts and get access to the cam tensioner, which I wanted to adjust back to where it should be.
But, as I walked to the front of the car I saw the little heat shield that sits on the exhaust manifold 🥴
Gitbag! I had a quick go putting it back on but the inlet manifold was getting in the way. Put to one side for another time.
It took me ages pratting around moving the ramp up and down to getting access each of the three engine mount to block, bolts and to get the mount itself out of the way. Once decent access was sorted I rotated the engine by hand (well, big ratchet!) a few times and set cylinder 1 to TDC to see it I could still pin the crank and cam. Happy days as both went in no problem whatsoever. Engine still in sync. Then sorted the tension back to where it was originally set.
Once set, I could look in to the injector chuff, which was not totally unexpected.
Full engine scan
Misfire on number 3. Looked at some live data….
….. not the best photo, but can clearly see that injector 3 is doing nowt. So; wiring, injector or other?!?
Did some multimeter checks
…. and decided it was the actual injector that’s the issue.
Quickly whipped out #3 from the head I had not long removed and set about removing the duff injector from the head that’s now on my block.
First up, rocker cover. Each time this has come off and been put back on it has been troublesome as it keeps getting caught on the opening to the inlet manifold
After battling for waaaaay longer than it should have, it eventually came off. Didn’t take long to whip out the duff injector, replace, torque down and set about getting that pesky rocker cover back on.
It went back on with a fight, as expected by now. I must be missing something…..
Back to the computer to wipe out the various codes and start again;
Quick flick of the key and back to running and almost sounding like it should 🤘The only thing I could hear that sounded off was what I usually end up finding to be an exhaust blow. Far from the end of the world at this point as the engine is running as it should be with no knocks or rattles, or the best a person with the hearing of a 100 year old can 🤣 In all honesty, I’ve had hearing aid upgrades recently that have made a marked improvement, so I would have heard it if it was there!
Very smokey at this point, but no blueness.
Left it idling for ages whilst tidying my tools away, periodically checking for warning lights on the dash and temp gauge, along with the live temperature reading through the snap-on ecu computer and occasionally grabbing the thermostat outlet pipe to check that the entire coolant system had opened. Nice and warm in the cabin, but fan yet to kick in. Probably needs a spin to get some decent temperature in to it. Maybe.
Smoking the place out
During one of my periodic check of everything I notice specs of oil on the rocker cover and underside of bonnet 😵 Seemed like the cam sprocket with spraying it everywhere. Panicked for a moment, then logic took over and quickly decided I must have snagged the rocker cover rubber gasket during the fight to get the cover back on.
Not the end of the world, but to sort this I decided I needed take off the inlet manifold, then fit the rocker cover and manifold again. It was too late on the day for this, so conceded defeat and accept I had to come back Easter Monday.
Back in this morning much to my surprise to see boss and mentor in the garage. Took the chance to start the car so they could have a listen and both agreed that despite being a little blowy, tue top end itself sounded good. Happy days and the validation (or more accurate, decent set of ears to confirm what I was hearing 😛 )
I started by cleaning all the oil off from topside. Checked the bottom and looked like the rear of the rocker had also been leaking as was all over the turbo, removed the TIP and inlet manifold. Once the rocker was off I could see my suspicions were correct. Gasket was clearly wet with oil.
All back together and looking clean and tidy.
Happy and confident all is well, I started her up again, this time fast idling with a bar on the accelerator. Again, periodically checking everything was a-ok.
Then, out the corner of my eye another oil drip 😞
Quick feel around and I had somehow left the third, hidden Allen bolt of the exhaust to turbo bolt out! Sorted that, another spray with brake clean and blow out and time for a test drive
Before so, check that the coolant level was ok, then saw this mess
Moron didn’t screw in the oil filler neck properly!
After a quick, friendly drive up and down the ring road I popped to my mentors house to discuss the smoke levels. He convinced me it will get better.
The only nagging thing at this lint is that I’ve not heard the fan kick in, with a code seek in the aircon module. I have half a clue on this, but not critical at this point. I wanted to finally have some of the bank holiday weekend. Drive home to pick Zee up in my car. Smoke levels showing signs of reducing. Back to the garage to pick her car up, but decided to go for a walk beforehand… then the pub for a pint and some food
35 miles driven so far, not once gone above 3.5k. Will get it in the garage after work tomorrow for a quick check over, then change the oil and filter at the weekend, along with another visual.
Still plenty more to do, but for now …..