2 1/4 Diesel serious smoking no power knocking from engine after replacing injector t

Hi I have just rebuilt the head on my series 3 21/4 Diesel new valves, valve seals reset tappets on first run up 2 injectors were blowing from copper washers i removed them and found copper washers damaged so replaced them (coated in grease to keep them in place) when started up there was a bad knocking noise from engine, smoke like youve never seen and lacking power run for a few miles and never cleared gthe injectors are only a few months old can anybody help please

are you sure theres only one copper washer and one steel washer per injector

I only fitted the copper washer 1 Off not the steel one not sure where it went

steel one fits in bottom of hole on top of injector shroud, it seals nozzle from combustion chamber ,running without will bugger nozzle, old ones can take some proggling out

Thanks for that, would it be ok to use grease to hold steel washer on to injector before inserting it in hole?

yes, though better dropped down hole with non magnetic screw driver or similar

ok will try that, hopefully havent buggered all injectors, Thanks for youre help

I tend to use a pointed metal prodder or a pencil to fit and remove the lower steel seals.
Sometimes I have found two seals in the one hole ! They must be fitted correctly or you get the symptoms you describe. Fit with the pressed "raised dome" uppermost.
The steel seals should go in easily there are some around that are to big on outside diameter and once fitted are impossible to remove. Any doubts get some more from a different supplier.

One way to get the old washers to part company with the bottom of the hole is to put a thin screwdriver down the bore, and put the end on the washer. Tap with a mallet. Do this in 2 or 3 spots and the washer will fold up enough to break loose.

did this on my 110 2.5D and it worked a treat. Don;t thump the screwdriver too hard - you do not want to cut through the washer, just distor it enough to get it to break loose from the layer of crap at the bottom of the hole.

ajr

Thanks for all you're advice replaced all seals correctly but no change lots of popping knocking and copious amounts of black smoke, this morning i stripped out old injectors and replaced with new started her up and the problem is still there haven't got a clue what to do next I think i can move away from injectors as the problem.

ok it was just steel washers had to be leaking if gas was passing injector ,black smoke is excess fuel or lack of air , tappet setting ie inlet valves not opening fully ,or butterfly valve not opening restiction in airfilter hoses etc will effect air entering,are you sure other injectors are good ,a tiny bit of dirt or combustion gas passing steel washer can spoil injectors ,new nozzles can be very poor quality nowadays,

Solved the problem, throttle linkage was incorrectly set causing air restriction, and overfueling, then on further investigation i started to reset tappets and noticed the 8th push-rod wasn't moving so I took off rocker shaft and found push-rod has gone down the side of the cam follower i managed to get it out by slowly turning cam and at the same time wiggling and moving push-rod about until it popped out i have ordered a new one and hopefully she should be running sweetly again