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Smoke after injector washer replacement

Discussion in 'Engine, Drivetrain, Fuel and Exhaust' started by tony19, Oct 15, 2012.

  1. tony19

    tony19 Active Senior Members

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    Location:
    Oxfordshire
    Your Mercedes:
    w203 220cdi
    My w203 had one of the injectors blowing.
    Removed it, cleaned the seating and got the new washers from dealer.
    Fitted it and torqued right with the new bolt and clamp and at 2000rpm was still blowing. So removed it and fitted 2 washers which it does not blow anymore but there is lots of smoke while iddle or driving.
    And the car seems a bit shaky when iddle.
    Could that be of the 2 washers?
    I tried to clean the seating properly with some carb cleaner and cloth.

    What could i try next...?
     
  2. jj1975

    jj1975 Senior Member

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    Location:
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    Your Mercedes:
    w203 c220cdi 2002

    Hi i had same problem injector 3 was leaking so i pulled it off cleaned the bore but to clean the seat of it i cutted you need a special tool for it and replaced the seal putted back all together and no problem after that from a month ago
    Maybe the injector it seating to high because you didnt but the seat and used 2 seals
     
  3. panason1c

    panason1c Senior Member

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    Your Mercedes:
    Mercedes ML270CDI, VW Polo 1.9tdi, BMW K1200RS
    Using 2 seals is likely the cause of the smoking, the spray pattern of the injector will now be out of parameter due to the raised seating of the injector. Clean the seat using a circle of emery paper glued to the end of an appropriate size wooden dowelling using a 'valve grinding in' action.
     
  4. Dosco

    Dosco Active Senior Members

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    I would be suggesting that you have all the injector seats re-cut and new washers and retaining bolts fitted any Indie would do this for you - STAR in Reading comes to mind as an excellent choice.
     
  5. Martin Jennings

    Martin Jennings Senior Member

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    Your Mercedes:
    C204 250 CDi AMG Prem Plus, W168 A160 Elegance LWB
    +1 Roger, the profile of the seats are very precise so have to be cleaned/cut properly. The smoke is definately the injector sitting too high as there are 2 seals.
     
  6. OP
    tony19

    tony19 Active Senior Members

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    Your Mercedes:
    w203 220cdi
    Thank you all for the advice.
    I will make the tool or buy it (if i can find it) and clean it over the weekend.
    Will post back the outcome.
     
  7. OP
    tony19

    tony19 Active Senior Members

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    Your Mercedes:
    w203 220cdi
    Quick question:
    Emery paper does it need to be meduim or fine, and how long should i do it for.
     
  8. OP
    tony19

    tony19 Active Senior Members

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    Location:
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    Your Mercedes:
    w203 220cdi
    Update:
    Bought the injector seat cutting tool off Ebay for £15 and done the job.
    Cutted the seat and a little the injector as it was deformed, new washer and its perfect.
    Checked, test driven it and its all good.
    Thanks all for the help :)
     

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