JTD MJet = knocking and excessive smoke
Have just rebulilt 1.9jtd mjet engine. Started it up 1st time today and was a very loud knocking noise from engine and clouds of very thick smoke from exhaust.
Car was started without auxulary belt fitted as I strained a muscle trying to get it on and was impatient.
A few points that may identify issues:-
a) - when timing belt fitted (using proper timing tools), the marks I had made on belt did not match up with marks on pulleys after 2 full revolutions by hand. I could not get them to stay aligned. The engine turned easily by hand with no obvious valve/piston contact and timing was still correct when timing tools re=installed.
b) Injectors were not marked for position when removed (by a previous mechanic, long story), is it important that these are fitted to original positions? Injectors have been out of car for 8 months, could this be a problem?
c) oil very old and thick, unable to do an oil change at home as nowhere to dispose of oil.
Having read a few posts a common knocking noise appears to be dirty/clogged injectors.
Replacement Cylinder head and cam housing - cylinder head has been cleaned, skimmed and tested, so no problems expected there.
The car was ran a few times this afternoon, and on some occasions there was no noise on idle, but very noisy at other times. Car ran on when turned off with key, if this gives any clues.
I am hoping not to take cam housing off again to check cams/lifters.
I am in Macclesfield if there is anyone in area willing to offer advice.
Can anyone give advise as I am desperate to get car back on the road.