fuel in the exhaust and misfiring

ClaireTheUnwise · 2025-07-20 11:49:03

Happy Sunday everyone one. Sadly I have run into yet another massive issue with this awful van.

I was going at almost 70mph on the way home from buying a welding kit to patch one of the outer sills when I had a sudden loss of power and tonnes of grey smoke out the back of the exhaust.

I couldn't stop without it being dangerous and since I was only 2 miles from home, I kept going at low speed and in the highest gear possible.

When I got home, I left it to sit and think about what it had done for a while before restarting.

On starting up and continuing, there is grey smoke that stinks of diesel and the engine sounds like it's misfiring .mile a lot, the thing is now undriveable...again

This sounds to me like it's either one of the injector nozzles or the high pressure pump throwing fuel in to at least one cylinder at the wrong time causing knock and unburned fuel. I tried tapping each injector with a bar and a small hammer to no avail.

My question is, how can I diagnose either which injector has gone bad or if it is the fuel pump?

Being a petrol person usually I'm unsure in diesels. I know enough that I have the PLN (pipe-line-nozzle) type injector type.

Also, how in the heck do you get that plastic intake manifold off? I know roughly where the bolt holes are, no idea on size and type of the heads though and I can't seem to fit any tools there..surely you don't have to pull the engine just to get that poorly designed manifold off right?

Anywho, this van is turning into a massive money pit and has solidified that I will never again buy anything but VAG..things which shouldn't be failing at this age and mileage (2006 and 133k) are all going wrong.

Citroen Dispatch 2006 with the 1.9 D

RegW · 2025-07-20 13:32:10

Why remove the manifold?
Just selectively back off the injector pipe nuts one at a time
as its ticking over presumably 'lumpily'
if no change, it's probably the bad injector
if it gets worse (lumpier) its a good injector.

Obviously, tighten the nut up again before going to the next injector.

Last edited by RegW (2025-07-20 13:34:22)

ClaireTheUnwise · 2025-07-20 13:36:08

Hi Reg,

Because the manifold is directly in the way of the injectors and there's no access without taking it off on the DW8.

Plus the upper and lower rocker cover gaskets have also perished and oil is all over the head.

Thanks for the tip of disconnecting each fuel line one by one though.

I'll admit, I'm close to sending this to the scrap yard. I have never had so many issues with a vehicle as I've had with this van.. I mean who's ever heard of a brake booster failure?

RegW · 2025-07-20 14:12:07

This is my first PSA van since a Citroen C15 (1.9D) years ago
and have the 2.0 DW10 in mine so have to rely on pics to know wtf is going on with others
and often have to make guesses.

I had 1.9 TDi VAG engined Galaxy previously and all the info I could ever need was easily obtained
including OBD stuff
If I could have put a van body on that I would have been very happy but swapped it for this one
which with same foot print but higher van body, seemed a good idea at first but I'm not impressed by them.

It's been reliable, but I have done the servicing and maintenance on it so reckon I deserve
some of that.
I hate the fact I've have had to struggle to get info and half decent wiring diagrams.

The 1.9 being bombproof is a fallacy IMO
Yes they're the simplest, but like any other engine, if abused or not maintained properly they'll fail
earlier than a well maintained one.
Also all our vans are old bangers now and suffer age related issues if not maintained and by the time we get them we can only hope they have some life left in them.

Last edited by RegW (2025-07-20 14:13:07)

kenbw2 · 2025-07-20 14:37:12

The manifold comes off quite easily - two bolts at the front and I think 3 behind the engine. They're deep in there so with an extension bar you'll get them

Once they're out, wiggle it a lot and it'll come out - I think there's rubber seals on the air intake that make it snug

ClaireTheUnwise · 2025-07-26 13:11:15

Well I got the manifold off.

For any one else..

Two 6mm allen heads for the front bolts, two 10mm hex heads for the rear.

I used my quarter inch drive kit from Halfords with the extension to reach them.

Just got all 4 injectors out.. I couldn't test by cracking one fuel line loose at a time because fuel was going everywhere. Instead I'm going to take them all up to the diesel specialist next week and see what they say. I had one with a sensor and the loom looks to be cracked where it meets the injector housing so it may just be the sensor telling the fuel pump to advance.

On the right side of the block, the head and block were covered with an oily substance but the rocker cover seal was clean..though it could be the lower. I have no chance of getting the covers off without taking the engine out so that's going to be an observe and hope it doesnt get too worse.

Plugged all the holes in the block with blue roll for now. Fingers crossed the injectors can be diagnosed and maybe repaired because they're unobtanium.

Also, all the copper crush washers came out with the injectors so I'll take that as a win.

Part numbers:

1x Delphi LDCR 02601AA1 with the sensor
3 x Delphi LCR 6736001

Last edited by ClaireTheUnwise (2025-07-26 13:14:43)

ClaireTheUnwise · 2025-08-11 23:02:12

Well I got the injectors refurbished by a diesel specialist, costed me £220 with some new spill off pipe and washers.

Fitted them this afternoon and.... No real change.

I've since stuck it on gumtree for scrap value, £350 Ono if anyone's interested.

Hopefully another idiot can take it on otherwise it's getting scrapped this weekend.

kenbw2 · 2025-08-11 23:44:31

If it goes to scrap maybe it's worth keeping the injectors since they're like new again

RegW · 2025-08-12 13:26:44

I understand your frustration with the thing, as I've had few nightmare vehicles too
But before throwing away your investment I suggest you check the pump timing is correct and
hasn't slipped to a retarded position which could cause the symptoms you describe.
It shouldn't cost you anything but some time to check.
I cant tell you the procedure exactly as I have a different engine but generally you pin/lock the crank
and camshaft with dowels (or drill bits), then check and/or set the pump timing using the marks
or whatever the manual says.

If you get it running well but you're sick of it, you can at least sell it and get more of your money back

Last edited by RegW (2025-08-12 13:32:18)

ClaireTheUnwise · 2025-08-16 20:33:02

Hi

I did check the timing when the initial fault occurred, it was spot on sadly.

I'm any case, the van has gone to the scrappy, though it did die around 100 yards from the entrance and required the forklift of shame to bring it into their yard.

Also, while parked, somehow the indicators and hazards had stopped working, typical french engineering for you. I used MK1 hand signals to get to the scrap yard.

Good luck all and thanks for the insight, I'm already eyeing up a T5 with no MOT going "cheap" so I'm sure my woes are only over briefly.

kenbw2 · 2025-08-17 00:47:58

ClaireTheUnwise wrote:

I'm already eyeing up a T5 with no MOT going "cheap" so I'm sure my woes are only over briefly.

What's the definition of insanity again? Good luck, hope you have as much fun with the T5 smile

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#1 2025-07-20 11:49:03

fuel in the exhaust and misfiring

#2 2025-07-20 13:32:10

Re: fuel in the exhaust and misfiring

#3 2025-07-20 13:36:08

Re: fuel in the exhaust and misfiring

#4 2025-07-20 14:12:07

Re: fuel in the exhaust and misfiring

#5 2025-07-20 14:37:12

Re: fuel in the exhaust and misfiring

#6 2025-07-26 13:11:15

Re: fuel in the exhaust and misfiring

#7 2025-08-11 23:02:12

Re: fuel in the exhaust and misfiring

#8 2025-08-11 23:44:31

Re: fuel in the exhaust and misfiring

#9 2025-08-12 13:26:44

Re: fuel in the exhaust and misfiring

#10 2025-08-16 20:33:02

Re: fuel in the exhaust and misfiring

#11 2025-08-17 00:47:58

Re: fuel in the exhaust and misfiring

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