Permanently smoky engine

[Pilchard]

Hi All

I'm new to the forum but have had my Bongo a few years now.
I have recently replaced the cylinder head gasket and had the head professionally skimmed and tested however after rebuilding the engine it is permanently smoky at higher revs.
I have been through the forums and found similar issues and on the advice given I have changed the air and fuel filters and cleaned the banjo filter. Prior to doing this my top revs were 2500. I am now getting 3000 but the engine is very lumpy at 3000. It runs very smoothly up to 2500 and doesn't appear to be smoky. The smoke doesn't disappear after running in for a half hour so I'm sure it is not a cold start or valve stem issue.
I have also replaced one of the broken vacuum solenoids 18-741C http://lushprojects.com/bongopartsmk2/c ... f02.html#6. It was the rearmost of the 2 solenoids sitting on top of the EGR pipe.
I have also fitted the blanking plates from Allan's.
The fuel in the tank has been sitting for 2 years although I have run a good quality diesel flush through the system
I'm getting to the stage where I almost want to scrap it but have put too much time, effort and money it to it up to now. Any thoughts or advice would be most welcome.
If all else fails are there any other engines I could fit.
I am based in Clackmannanshire so quite close to Lawson Diesel in Edinburgh but as the vehicle is on a SORN at present I can't get it through there.
Thanks

Kenny

[Simon Jones]

Welcome to the forum . The first clue is the colour of the smoke. Have a read of this and see if that helps:

http://www.uniteddiesel.co.uk/diesel-engine-smoke.php

[Pilchard]

Good site. Going by the chart it looks like I may have turbo problems.
Thanks for the link.
Kenny

[The Great Pretender]

Could your in tank filter be causing your problem?

[Pilchard]

Not the in tank filter as it is oozing oil out the inlet manifold where it connects to the inter cooler but I did check that in my earlier head scratching moments. It's not valve stems either cause even after an hour hard running it is still smoky.
Kenny

[winchman]

You can drive it whilst on SORN providing its booked in to the garage and you go straight there

[Northern Bongolow]

poor quality air filter maybe. or
take some of the pipes off between the turbo and the inlet manifold see how much oil is in there. they have been known to dump the oil vapours into the inter cooler and fill it up, remove and rinse out.
check every clip/connection on the air pipe from turbo to inlet manifold, if any leaks are present it will cause the oily air to stall and cool instead of being forced through and burnt.
check the little pipe that runs from the fuel pump top diaphragm to the inlet manifold, remove the diaphragm and clean out the oil thats present. and the little pipe at the end of the vac solenoid run that goes into the air pipe at the rear of the head (drivers side) with the little green one way valve fitted, the little nipple breaks off leaving it sucking air.
check the black pipe that goes round the rear of the head (under the heat foil) it may have a melted hole in it.

iff it sucks/leaks air in through a leak its not getting rammed air from the turbo.

could be fuel pump seals, is it wet underneath, or the pump nose seal sucking air.

[Pilchard]

This all ties in with my other post about pistons. I think I need to investigate the pipe work before cracking into the engine again. Time to roll up the sleeves and dig out the boiler suit.
Thanks for your help

Kenny