Common-Rail Injector Blow-By and Seal Failure
SeriousFuel SystemThe copper injector sealing washers on 2.2 and 2.4 TDCi Duratorq engines degrade over time, permitting high-pressure combustion blow-by gases to escape up the injector body. This forms hard carbon deposits known as 'black death', risks bore wash, and can cause piston crown melting.
Pungent diesel or exhaust fumes entering the cab through ventilation ducts, Rhythmic chuffing or ticking sound from the cylinder head area at idle, Thick tar-like black carbon buildup around the base of the fuel injectors
- Remove top engine cover and inspect injector wells for black carbon deposits or wet diesel
- Listen closely for chuffing blow-by sounds around each cylinder injector seal when idling
- Check cold-starting behaviour and ensure no excessive grey/white smoke on startup