Jeffbeck

This came out of a 2005 smart fortwo 0.8L diesel CDI engine with 89,000km. Head has been inspected and rebuilt. The valve and valve seats have been resurfaced, and installed with new valve seals. Comes with camshaft, rocker arms, and caps. Thought I would use it on a project car but canceled those plans. $800obo bechven@Hotmail.com

Just installed 3 new injectors and the smart runs great! Who would have thought that there would be 6 bad injectors between 2 smarts!I got the injectors from Fred Holms in Vancouver, BC. Great place to deal with! Raj there said that the Canadian diesel is brutal on the high pressure pump and injectors. He said that I should expect 100-150K before the injectors will need replacement again. He suggested using a fuel conditioner to improve lubricant properties of the fuel.Horay! The problem is solved! Will add pics once I am completely done with the repairs

[Omg! I thought that the metal was from the fuel pump! I have swapped the high pressure pump already. I hope that there is no more bits left in the system! Thanks for the info! Will let you know how it goes

I suspect the same things... I just wish that the injectors were serviceable. I took out the new (known good injector) and replaced with the best looking injectors I had between the 2 cars. I added a lot of cetane booster and the car started and stayed running (like a stuck egr), but struggled to get up to speed. I then filled the tank up with fresh diesel to dilute the boost/cleaner... the car had a severe lack of power within a block (2x worse than a bad egr). Was able to limp it home, and tomorrow I am going to order 3 new injectors.

Thanks for all the ideas . The ECM needs to be coded with the SAM and then with the remote keys. I spoke with Raj and Fred Holmes in BC and he recommended that I replace all injectors because they are very common to all have problems at the same time. I think he is right! I tried the cleaner in the tank and it has gotten better, but the car still runs poorly with very little power. I am surprised that such expensive components are worn out so quickly. Is it typically a 100k service interval for injectors and timing chain/sprockets?

I'll pick up some cleaner and try that out. With the new 1 new injector it will rev to max, but it is slow on the climbing rpm and smokes lots! Not much power either, will barely make the climb up the driveway (which is a lot better than barely running. I am wondering what would take out 3 injectors... Debriefs and soot, or possibly the over compression of the previous engine caused the injector failure....

I have been able to borrow a new injector to replace the wet tipped one and the smart started up and revved up better, but still not right. I just thought that the chances of having six bad injectors between two cars would be close to impossible. I guess I was wrong! If anyone knows where I can buy these injectors please send me a link! On the injectors that I suspect as the worst, they come out of the cylinder wet everytime... and the exhaust smells very rich.Is leakage the most common failure? Has anyone ever done these tests at home before? How do I do them?

Yes, that is correct, the chain and sprockets are new. The oil jet on the tensioner was free of debris when I checked on assembly. I rechecked the timing and it is good.

I put a new turbo on the car as well.... yes, more parts. I was wondering about a blocked intercooler so I have the inlet to intake manifold pipe off currently. I pulled the exhaust pipe off as well and it was the same running feeling.

The chain and the cam sprocket looked worn, teeth starting to curl and spread open.

Thanks again for all the new ideas of checking things. I have a feeling that the parts vehicle I swapped injectors with were no good. All the tests lead me to believe that the injectors are no good. After running it for 15min, I pulled the injectors out and 2 had carbon on the end and were dry. I then swapped them around and the same two injectors were dry with new carbon build up. I tried swapping the other 3 injectors from the parts car, and they came out wet everytime but the car ran a bit better or worse with each one.... Dealer pricing for an injector is an insane $850/ea.... I suspect that just the tips need to be replaced. Does anyone know where the tips can be purchased or a place that is setup to bench test the injectors? I am in Calgary, Alberta, Canada.

That is an interesting idea! I have already checked the grounds, but not the power supply. I will get the multimeter out and check into this!

NEW INFORMATION!!!I decided to try to keep the car running with by spraying brake clean in the intake when it was about to stall. I was able to nurse it to stay running past the 6-10 seconds then I was able to get it to stay running. I let it warm up to the first bubble then tried to rev it up, but it would start to shake and smoke when I did this. I added more engine load by turning on the seat heaters, defrost and blower motor.... this would practically stall out the engine. I was able to restart the smart, but it still wouldn't allow me to rev it up. The exhaust was thick, my eyes watered terribly. It was like it would begin to misfire as soon as throttle was applied, the best I could get was 12-1500rpm.

We just had our first real snow of the year here (Calgary, Alberta, Canada), so I left the smart to soak in the hot tub. I began thinking about the injection timing, and how that relates to the ECM, which is signaled by the crank sensor. I have seen intermittent crank sensor problems but they typically get better with higher speeds (maybe with a few misses). Anything is possible, so I swapped the crank sensor over with high hopes.... but the same condition persists. Prolonged cranking, rough start, begins to idle normally, accelerator pedal hardly responsive, begins to shake alot then stalls out. I more thing to mention, the exhaust is very smoky at the startup, gets clean at the idle, then gets smokey at the end. Maybe good info, maybe just more confusion.

Soooo.... I swapped out the high pressure pump and nothing different. The only thing left is electrical issues, I took the wiring loom apart that connected the injectors... all looked good...I am at a complete loss! I am unfamiliar with how to graph the hipressure pump, but will see if I can get it and post.