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4m40 motor smoking


 
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alpujarra
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Joined: 17 Nov 2018
Posts: 8
Location: Spain

PostPosted: Sat Dec 01, 2018 13:50    Post subject: 4m40 motor smoking Reply with quote

Hi all, Hoping someone may be able to help.
I have a 2.8 td 1996 4m40 engine..... and it failed ITV here in Spain because of black smoke coming out...Sad

Having read most articles here, couldn't find an answer..... 171,000 miles   bought at 96,000 miles and to my knowledge no injection pump or injectors serviced....! Still doing around 25 -28 to the gallon including 75 MPH motorway driving....
I have taken off rocker cover and flushed filter in the top with petrol and then paraffin.... flows through very easily.
So thought I would disconnect the breather and run it into a bottle to see if there was crankcase compression.....
After maybe 150 miles, a tiny smattering of oil, not even a teaspoon in the bottle, BUT, I have oil coming from around the oil filler which seems very strange. I have wiped this off a few times but every time I open the bonnet there is more...
This was not happening before disconnecting the breather pipe.
I have a noisy turbo which has been like it now for at least two years but does not seem to affect the performance. There is no oil at all showing on top the turbo vane.
I have had oil coming out from somewhere at the back of the engine for a long time and only just realised that there is a valve there at the back of the inlet manifold.... I thought that originally it was leaking from the rocker gasket but maybe from that valve.... it's difficult to tell.
So anyone any ideas what could be the cause of the black smoke???

Thanks in advance
Graham
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PostPosted: Sat Dec 01, 2018 13:50    Post subject: Google Ads keep the POCUK free to join!


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emax
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Age: 67
Zodiac: Taurus
Joined: 02 Aug 2007
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PostPosted: Sat Dec 01, 2018 21:50    Post subject: Reply with quote

Hello.

Have a look at this one.

http://www.pocuk.com/forums/viewtopic.php?t=168388&highlight=
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Simon_W
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Joined: 21 May 2013
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PostPosted: Sat Dec 01, 2018 22:29    Post subject: Reply with quote

1. There's a pressure relief valve on the rear of the inlet manifold that can splatter oil onto the bulkhead. Best to remove it, clean it, check it over and fit it back.
2. Has the EGR valve been removed and blanked off? The EGR valve is prone to clogging and this can cause smoke. If it's there, remove it and clean it thoroughly. If Spanish regulations allow it, you could remove it and fit an EGR blanking kit.
3. There might be a residue of oil in the intercooler.  Remove it and wash it through with white spirit.  Vent it thoroughly before refitting.
4. I think there's a gasket under the oil filler. Make sure it's in good order.
5. If the turbo's noisy, it could be allowing oil into the inlet manifold.

It's really just a matter of elimination. The chances are that it's oil getting into the inlet that's causing the problem rather than a problem within the engine itself.
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alpujarra
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Joined: 17 Nov 2018
Posts: 8
Location: Spain

PostPosted: Wed Dec 05, 2018 13:37    Post subject: Thanks Reply with quote

Simon_W wrote:
1. There's a pressure relief valve on the rear of the inlet manifold that can splatter oil onto the bulkhead. Best to remove it, clean it, check it over and fit it back.
2. Has the EGR valve been removed and blanked off? The EGR valve is prone to clogging and this can cause smoke. If it's there, remove it and clean it thoroughly. If Spanish regulations allow it, you could remove it and fit an EGR blanking kit.
3. There might be a residue of oil in the intercooler.  Remove it and wash it through with white spirit.  Vent it thoroughly before refitting.
4. I think there's a gasket under the oil filler. Make sure it's in good order.

5. If the turbo's noisy, it could be allowing oil into the inlet manifold.

It's really just a matter of elimination. The chances are that it's oil getting into the inlet that's causing the problem rather than a problem within the engine itself.


Thanks Simon for your input.....
I will see if i can find a spanner big enough for the pressure relief valve....Smile
I'll have a look in the intercooler, but don't remember it being at all oily.
EGR blanked off 9 years ago....
Oil filler I've never had a problem with before, that's the strange thing........I thought at first it was just the paraffin blowing out.... but it's not.
Wondering if because the breather tube goes up higher than the oil filler, maybe the oil takes the easier path.....
There appears zero oil in the turbo, taking the hose off..... clean as a whistle.

I'll have another look at the beast now we have some good weather again at last... no garage......Smile
Cheers
Graham
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alpujarra
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Joined: 17 Nov 2018
Posts: 8
Location: Spain

PostPosted: Wed Dec 05, 2018 13:39    Post subject: Thanks Reply with quote

emax wrote:
Hello.

Have a look at this one.

=168388&highlight=


Thanks for the link Emax, I will check it out...
cheers
Graham
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alpujarra
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Joined: 17 Nov 2018
Posts: 8
Location: Spain

PostPosted: Thu Dec 06, 2018 13:51    Post subject: Re: Thanks Reply with quote

alpujarra wrote:
Simon_W wrote:
1. There's a pressure relief valve on the rear of the inlet manifold that can splatter oil onto the bulkhead. Best to remove it, clean it, check it over and fit it back.
2. Has the EGR valve been removed and blanked off? The EGR valve is prone to clogging and this can cause smoke. If it's there, remove it and clean it thoroughly. If Spanish regulations allow it, you could remove it and fit an EGR blanking kit.
3. There might be a residue of oil in the intercooler.  Remove it and wash it through with white spirit.  Vent it thoroughly before refitting.
4. I think there's a gasket under the oil filler. Make sure it's in good order.

5. If the turbo's noisy, it could be allowing oil into the inlet manifold.

It's really just a matter of elimination. The chances are that it's oil getting into the inlet that's causing the problem rather than a problem within the engine itself.


Thanks Simon for your input.....
I will see if i can find a spanner big enough for the pressure relief valve....Smile
I'll have a look in the intercooler, but don't remember it being at all oily.
EGR blanked off 9 years ago....
Oil filler I've never had a problem with before, that's the strange thing........I thought at first it was just the paraffin blowing out.... but it's not.
Wondering if because the breather tube goes up higher than the oil filler, maybe the oil takes the easier path.....
There appears zero oil in the turbo, taking the hose off..... clean as a whistle.

I'll have another look at the beast now we have some good weather again at last... no garage......Smile
Cheers
Graham


UPDATE!

Hi again Simon

Well I had a good look around yesterday,
Ran the engine without inlet hose connected to inlet manifold and still had some smoke coming out the back.... maybe residue?
Couldn't undo valve on end of inlet manifold.... managed to get a small pair of stilsons on the nut with 300mm tube on handle but couldn't budge it....
Also ran the engine with the oil filler cap off on tickover.......... wow the amount of oil spitting out off the rockers was amazing and so wondering  if there may be too much oil pressure. It went all over the place and spitting out around a metre...!
Is that possible? Is there a pressure relief valve on the oil flow? So did a search here and could not find any definitive answers....
yet, still no amount of oil coming out through the breather pipe into bottle.... just a small smattering in the bottom. That's over 7/8 hours running with 5 hours on motorway, and no air filter in.....
Maybe there is something which is restricting oil flow and increasing oil flow to the cam?
Okay I can change the filter, I have another new one....
I have found a rubber seal to put on the oil filler but no chance to try it yet.
So where to go from here.....?
ANy ideas?
Cheers
Graham
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alpujarra
Newbie
Newbie




Joined: 17 Nov 2018
Posts: 8
Location: Spain

PostPosted: Thu Dec 06, 2018 13:52    Post subject: Re: Thanks Reply with quote

alpujarra wrote:
Simon_W wrote:
1. There's a pressure relief valve on the rear of the inlet manifold that can splatter oil onto the bulkhead. Best to remove it, clean it, check it over and fit it back.
2. Has the EGR valve been removed and blanked off? The EGR valve is prone to clogging and this can cause smoke. If it's there, remove it and clean it thoroughly. If Spanish regulations allow it, you could remove it and fit an EGR blanking kit.
3. There might be a residue of oil in the intercooler.  Remove it and wash it through with white spirit.  Vent it thoroughly before refitting.
4. I think there's a gasket under the oil filler. Make sure it's in good order.

5. If the turbo's noisy, it could be allowing oil into the inlet manifold.

It's really just a matter of elimination. The chances are that it's oil getting into the inlet that's causing the problem rather than a problem within the engine itself.


Thanks Simon for your input.....
I will see if i can find a spanner big enough for the pressure relief valve....Smile
I'll have a look in the intercooler, but don't remember it being at all oily.
EGR blanked off 9 years ago....
Oil filler I've never had a problem with before, that's the strange thing........I thought at first it was just the paraffin blowing out.... but it's not.
Wondering if because the breather tube goes up higher than the oil filler, maybe the oil takes the easier path.....
There appears zero oil in the turbo, taking the hose off..... clean as a whistle.

I'll have another look at the beast now we have some good weather again at last... no garage......Smile
Cheers
Graham


UPDATE!

Hi again Simon

Well I had a good look around yesterday,
Ran the engine without inlet hose connected to inlet manifold and still had some smoke coming out the back.... maybe residue?
Couldn't undo valve on end of inlet manifold.... managed to get a small pair of stilsons on the nut with 300mm tube on handle but couldn't budge it....
Also ran the engine with the oil filler cap off on tickover.......... wow the amount of oil spitting out off the rockers was amazing and so wondering  if there may be too much oil pressure. It went all over the place and spitting out around a metre...!
Is that possible? Is there a pressure relief valve on the oil flow? So did a search here and could not find any definitive answers....
yet, still no amount of oil coming out through the breather pipe into bottle.... just a small smattering in the bottom. That's over 7/8 hours running with 5 hours on motorway, and no air filter in.....
Maybe there is something which is restricting oil flow and increasing oil flow to the cam?
Okay I can change the filter, I have another new one....
I have found a rubber seal to put on the oil filler but no chance to try it yet.
So where to go from here.....?
ANy ideas?
Cheers
Graham
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Simon_W
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Joined: 21 May 2013
Posts: 4881
Location: Watford

PostPosted: Thu Dec 06, 2018 16:26    Post subject: Re: Thanks Reply with quote

alpujarra wrote:

UPDATE!

Hi again Simon

Well I had a good look around yesterday,
Ran the engine without inlet hose connected to inlet manifold and still had some smoke coming out the back.... maybe residue?
Couldn't undo valve on end of inlet manifold.... managed to get a small pair of stilsons on the nut with 300mm tube on handle but couldn't budge it....
Also ran the engine with the oil filler cap off on tickover.......... wow the amount of oil spitting out off the rockers was amazing and so wondering  if there may be too much oil pressure. It went all over the place and spitting out around a metre...!
Is that possible? Is there a pressure relief valve on the oil flow? So did a search here and could not find any definitive answers....
yet, still no amount of oil coming out through the breather pipe into bottle.... just a small smattering in the bottom. That's over 7/8 hours running with 5 hours on motorway, and no air filter in.....
Maybe there is something which is restricting oil flow and increasing oil flow to the cam?
Okay I can change the filter, I have another new one....
I have found a rubber seal to put on the oil filler but no chance to try it yet.
So where to go from here.....?
ANy ideas?
Cheers
Graham


Hi Graham
I've never run my engine with the oil filler cap off, so I can't give you an answer as to how far the oil gets flung! I am not surprised it goes a long way. I badly fitted the banjo joint for the oil pipe to the chain tensioner, and it made a real mess.

If you know the turbo has been making strange noises, then maybe that's the culprit and it's not giving enough boost to allow the fuel to combust properly. Otherwise you may be looking at an injector or pump issue.

Maybe time to consult a local diesel specialist?
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