Smoking Carnival diesel

[JO FOURIE]

I had some engine trouble which I think was due to a previous incident when the service agent replaced the timing belt and they broke the jockey pulley bolt. They repaired it and the bolt broke again while driving. Another service agent got it going and reported no cylinder head damage.

The rocker pin fell out and jammed the cam shaft. The visible damage was cambelt that came off sprockets.

I opened the engine after a long struggle. Is am now well knowledgable to replace cam belt.

I opened the tappet cover and found 4 rockers broken and bent rocker shafts.(Some damage most probably from previous incident)
I replaced the damaged parts.

The engine now struggles to start. I used a damp petrol cloth held in front of intake to get the engine started. It puffs a lot of white smoke and is fairly uneven at low rpm when cold. I ran the engine to operating temperature and the smoke got less but was still there. It idles ok when hot and revs up.

I think it might be diesel pump timing but rechecked the timing marks and made sure that it is correct.

I am reluctant to pull the head. My logic says it is most probably bent valves.

Can anyone tell me how to check if it is a valve problem? I understand that a diesel compression test is fairly involved. A normal handheld compression meter is not sufficient. Diesel compression too high.

Any suggestions?

[bruno1926]

If its a 2.9 TDI and it comes to it I have an head for one of these .If you need it we can come to some compromise over the cost. It has all the valves in it.

[JO FOURIE]

Thanks for the proposition.(I am living in South Africa and will be cheaper to buy spares locally)
I actually managed to find the problem.
It was diesel pump timing.
I measured compression with hand held tester but only managed to measure approx. 19bar on each cylinder.(Diesel compression too high for gauge and hand pressure) The fact that all four cylinders produced similar pressures, indicated that it is unlikely to be bent valves.
I struggled a lot and decided to take a chance to advance the diesel pump timing with approx 2-3teeth on the belt. Wallah, the destinct diesel crackle sound immediately told me all is ok and all the white smoke was gone.

FACT : If you loose a timing belt on a 2.9 Tdi Carnival the chance of valve damage is most unlikely. The damage will be a few rockers and bent rocker shafts.(Happened twice to me with no valve damage)

If anyone try DIY on timing belt I have the following tips:
1. Diesel pump timing is not exactly at " 3 o clock". It is difficult to see the actual mark on the back cover. Actual setting is approx at 3 o clock plus 2-3 teeth.
2. Do not start engine without crank pulley fitted. It guides the belt and belt will come off if not fitted.
3. White smoke indicates too slow diesel pump timing and difficult to start when cold.

Tip for injector removalNot required for belt removal, but to access rockers one has to remove tappet cover and thus the removal of injectors required)
I struggled to remove the injectors due to carbon build up and rust. I used a pipe with bolt welded on one side to screw onto injector and a thick washer welded as stopper on the other end. Use something heavy to slide onto pipe and "hammer" injecter out.

I you struggle to get the engine going after diesel pipes and injector removal and refitting, hold a cloth dampened with normal gasoline at intake. The fumes let the engine start very quickly. Remember to take safety precausions.