Injector problem 2006 3.0d, lots of smoke

[Yarno]

Alright, I have been having some dramas with my 2006 3.0d.

I had the exhaust manifold replaced a week ago as it was cracked as they usually do. The mechanic needed to remove the fuel rail and injectors to get to it apparently.

Since then (from the day that I picked it up) it blew smoke on start up and had a ruff idle, it also gave an injector warning (I read the codes and it was fuel rail pressure low).

So I took it back to the mechanic and they had a look checked the codes and said it's the glow plugs making it smoke. I already knew 9 months ago 3 of them were faulted, but this had never caused a problem. So they changed the glow plugs and it fixed most of the smoking, but the ruff idle and more smoke than before the manifold change was still present and also the fuel pressure low fault and an oil pressure low/check oil level came up in the morning, these were not at the same time..

I took it back again and told them the symptoms and this time they just cleared the codes and removed the performance chip which was installed on the fuel rail and told me to see if it was any better.

I drove for a few more days, only about 40km a day, I still notice the ruff idle but didn't have any other problems, maybe just a little smoke on startup.

Today I started it up, I got the low engine oil pressure warning turn off engine, so i did just like last time it came up, I told me after I got to work to check oil level as it was low, I checked it, it was fine, I drove a couple hours latter the ruff idle was still present but maybe a little worse. Coming home this afternoon, I stopped at the shops, started it again and the ruff idle happened, but when I drove off I heard a reasonably loud clicking sound and looked behind and there was a massive smoke screen that had been produced, I stopped the engine straight away , had a look under the bonnet and opened the oil fill cap, there was only a small amount of smoke coming from here. So I decided to start it again as I couldn't find anything else. It started fine and ran normal for about 2 seconds and the clicking started again and masses of smoke came from the exhaust (looked whitish I guess so it's unburnt diesel), switched it off and pushed it into a carpark.

So this is where I am at now, not sure what to do, I am going to get it towed to the same mechanic.

I also had purchased a couple of injectors which I was hoping were going to fix it, but now I'm not sure.

Does anybody have any ideas?? I think one of the injectors may have been damaged while it was out, but what could the clicking be, it doesn't sound anything like a big end, but does sound like when you put a car in park while moving.

Oh it has 180000km on the clock, had regular services.

[powers1]

Originally Posted by Yarno

Alright, I have been having some dramas with my 2006 3.0d.

I had the exhaust manifold replaced a week ago as it was cracked as they usually do. The mechanic needed to remove the fuel rail and injectors to get to it apparently.

Since then (from the day that I picked it up) it blew smoke on start up and had a ruff idle, it also gave an injector warning (I read the codes and it was fuel rail pressure low).

So I took it back to the mechanic and they had a look checked the codes and said it's the glow plugs making it smoke. I already knew 9 months ago 3 of them were faulted, but this had never caused a problem. So they changed the glow plugs and it fixed most of the smoking, but the ruff idle and more smoke than before the manifold change was still present and also the fuel pressure low fault and an oil pressure low/check oil level came up in the morning, these were not at the same time..

I took it back again and told them the symptoms and this time they just cleared the codes and removed the performance chip which was installed on the fuel rail and told me to see if it was any better.

I drove for a few more days, only about 40km a day, I still notice the ruff idle but didn't have any other problems, maybe just a little smoke on startup.

Today I started it up, I got the low engine oil pressure warning turn off engine, so i did just like last time it came up, I told me after I got to work to check oil level as it was low, I checked it, it was fine, I drove a couple hours latter the ruff idle was still present but maybe a little worse. Coming home this afternoon, I stopped at the shops, started it again and the ruff idle happened, but when I drove off I heard a reasonably loud clicking sound and looked behind and there was a massive smoke screen that had been produced, I stopped the engine straight away , had a look under the bonnet and opened the oil fill cap, there was only a small amount of smoke coming from here. So I decided to start it again as I couldn't find anything else. It started fine and ran normal for about 2 seconds and the clicking started again and masses of smoke came from the exhaust (looked whitish I guess so it's unburnt diesel), switched it off and pushed it into a carpark.

So this is where I am at now, not sure what to do, I am going to get it towed to the same mechanic.

I also had purchased a couple of injectors which I was hoping were going to fix it, but now I'm not sure.

Does anybody have any ideas?? I think one of the injectors may have been damaged while it was out, but what could the clicking be, it doesn't sound anything like a big end, but does sound like when you put a car in park while moving.

Oh it has 180000km on the clock, had regular services.

Lets start from the beginnng!You car was fine when it went in to replace the cracked manifold,right!All your smoke issues and low fuel pressure error readings, happened after !They also say that they removed the injectors.

The rough idle ansd white smoke is all fuel related ,so get them to admit they screwed up ,cause your car was fine when it went in!They could have damaged a wire or the pressure sensor ,they could also have disconeected some vacuum pipes,but difficult to tell but they just need to go in stages of elimination !
The glow plugs are only needed at very low temperatures!They would cause white unburnt diesel smoke ,on starting ,never when engine upto temperature!The clicking noise could be the injector ,injecting diesel at the wrong timing .

The "performance chip" as you call it ,is actually a box that increases your fuel pressure and is connected as a bypass on your fuel pressure sensor on the rail,so with faulty injectors and this plugged in ,you get more smoke,which was why the car was better when they unplugged it!

The low level oil warning you got ,could be a faulty oil pressure sensor ,which is common with these!Mine also gave me low pressure error a few years ago and been fine ever since,so just check the oil level and if its fine,then dont worry!

Get them to replace your oil breather filter,if it hasnt been done.Also smell the smoke..!Is it diesel smell or oil?

[Skier1]

You could tell them that there is no need to remove injectors and fuel rail to replace the exhaust manifold.I recently changed my manifold and done it all from underneath.On top I only needed to remove the cover on top of the engine and the air filter covers.Sounds like they stuffed something up ,possibly one of the vacuum/pressure lines from the turbo actuator.

[Yarno]

Ok so I went to the car this morning and decided to start it before I organise a tow. So I start it and it runs fine. I let it idle for a minute and gave a couple of good revs and everything was perfect not even the ruff idle was present. So this happened yesterday after about 20mins of driving and a restart.
I'm thinking I'll drive it to the mechanic as its about a 15min drive.

[powers1]

Originally Posted by Yarno

Ok so I went to the car this morning and decided to start it before I organise a tow. So I start it and it runs fine. I let it idle for a minute and gave a couple of good revs and everything was perfect not even the ruff idle was present. So this happened yesterday after about 20mins of driving and a restart.
I'm thinking I'll drive it to the mechanic as its about a 15min drive.

Very strange..Anyway ,hope its stays good

[Yarno]

Seam to be fixed now, bought a set of reconditioned Bosch injectors and had them installed. Have also put the performance chip back on and all is good.

I think from what and injector specialist said was that it would have been one of the coils that was playing up.

[powers1]

Nice you got it sorted

[deepblonde]

Originally Posted by Skier1

You could tell them that there is no need to remove injectors and fuel rail to replace the exhaust manifold.I recently changed my manifold and done it all from underneath.On top I only needed to remove the cover on top of the engine and the air filter covers.Sounds like they stuffed something up ,possibly one of the vacuum/pressure lines from the turbo actuator.

That is impressive that you managed to change your exhaust manifold from underneath, without removing injectors or intake manifold? Did you put your X5 just on stands or hoist it up? I wish I lived in Newcastle , I'd pay you to do mine!

[Skier1]

Originally Posted by deepblonde

That is impressive that you managed to change your exhaust manifold from underneath, without removing injectors or intake manifold? Did you put your X5 just on stands or hoist it up? I wish I lived in Newcastle , I'd pay you to do mine!

I put it on blocks about 6" high on all four corners ,it made it just the right height ,not too high and not too low,set up a comfy little bed under it with a pillow to rest the head at times and went from there .It wasnt a bad job to do at all ,dont even think I swore at it .Done a bit of work from the top but probable 60% to 70% from underneath ,no way did i want to remove all the injectors etc .