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Discussion Starter #1
Hi all,

I'm having a few issues with my old Expert van. I recently decided to put a new second hand engine in after the old one blew. The problem is when fitting the new engine I had to transfer the old injectors across and the washers with it are pretty degraded. This is creating a lot of smoke, mostly when idle, and a bit of miss-firing.

I've tried to get a injector seal kit from Peugeot, but they are not supplied anymore.

Has anyone got any thoughts on what I could do? I have heard you can heat the copper rings back up to soften them, the problem is the rubber o-rings. I'm sure there has got to be some out there that will fit, it's just hard to work out without measurements of new o-rings when looking online and I don't want to waste money by buying loads in hope one will fit.

Oh and it's a XUD 1.9 TD engine (90bhp).

Any thoughts or advice will be greatly received.

Many thanks,

Martyn
 

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An xud engine has no o rings its just the copper seal and heating them up is all that would be necessary there is also a small wavy washer in the middle but no O rings

I doubt the seals are the reason for your smoke.

XUD turbos can have bosch or lucas fuel systems and they cannot be mixed also there are various pressure ranges on them are you sure you have the correct match ?
 

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Discussion Starter #3
Thanks reliable406,

I had just assumed it had rubber o-rings, but will be taking the injectors out tomorrow and will investigate the fuel system too. What's the best way to check if it matches? I am pretty sure I got the right engine to swap with the existing one.

Thanks again,

Martyn
 

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Its nothing to do with the engine as to what injectors it has its down to fuel system and power output

Are you using the full engine with pump and injectors it came with ?
 

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Discussion Starter #5
No the engine was supposed to come complete, but it was missing the injectors, so I had to transfer these across from the old engine. I also replaced the fuel pump with a new one
 

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So you have a new pump with your old injectors that may be your issue as the opening pressure of the injectors can vary depending on age and power output as well as bosch and lucas systems being different.

Its much better to fit complete engines with these to avoid fueling issues

Post up a pic of the pump and injectors
 

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Discussion Starter #7
Ok thanks, I'll try and get a few pics up tomorrow. Would new injectors help then? How do I find out which fuel system I have?
 

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The pump and injectors are matched to each other your new pump may not be correct you have simply added more maybes into the mix using your original pump and injectors would probably be best bet but some pics would help identify what you have at moment

There is also a 3 digit code on a tag on the engine DHY DHX D8A D8B etc this will tell you if you have a matching engine or not as believe it or not you could have 1 of at least 10 different versions !
 

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Discussion Starter #10
This is all so very helpful, thanks. I'll try and get the details here tomorrow and also find part numbers for new fuel pump.
 

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Discussion Starter #11
I spoke to the mechanic that put the new engine in and he said he didn't fit the new fuel pump and instead put the one from the old engine on. So the fuel pump and injectors should match. I've had some issues getting the injectors out, but am borrowing a very deep socket, because most of the ones I found weren't deep enough. There's a local garage that specialises in Peugeot, so I'm hoping they can help find a suitable replacement for the aluminium crush washers, because these are apparently pretty flat now.
 

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So you have the original pump and injectors on the replacement engine in that case i would be checking the pump timing and all the boost pipes are secure as a boost leak will cause smoke.
 

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Discussion Starter #13
Ok that's great, I'll look into that tomorrow if the smoke continues after hopefully changing the washers. I'll keep you posted how it goes. Thanks again for your time and advice
 

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Washers will not help the smoke honestly unless there is an obvious combustion leak its not worth messing with the injectors for now.

You say its a turbo diesel are you certain of that and if so are you certain the replacement was a turbo engine as the compression ratio is different between turbo and non turbo even though engine looks and basically is the same
 

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Discussion Starter #15
The mechanic was suggesting the combustion wasn't very high and with running it for a while the smoke reduces. It is definitely a turbo as well, both engines that is. I'm sticking with the washers for now because the mechanic has spent many hours on it, so I'm trusting his judgement for now, he also said the old ones are pretty damaged. I've managed to find somewhere to get the copper and crush washers matched. Hopefully that will sort it, I'll let you know when the new ones are in place. Got the injectors out, it's pretty dirty in there, but can't now get the washer out without a tool or large bolt to screw into it.
 

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Any diesel workshop should have a source for the washes as they are used in all old style engines ford peugeot renault fiat bmw opel diggers trucks busses generators boats everything :)
 

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Discussion Starter #17
That's great thanks. I found a diesel specialist that can match then, bit of a drive away, but all sorted now on the washers front
 
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