300tdi smoke machine

Aplogies if thisnis in the wrong forum.

My newly aquired defender 90 with a 300tdi in it smokes like a machine.
Beleived to be a turbo fault so replaced turbo and intercooler due to the amount of oil. Still smoked so got the head checked which was found to have a crack in it, replaced for new with all new valves etc included. Still smoked so pulled the engine out and checked bores etc, deep groove on cylinder 2 so thought iv gone this far may aswell fork out for a full recon short block. So with a new turbo/Intercooler/cylinder head/short block/timing kit it still bloody smokes (neighbour complained during testing ) I'm 100% sure the timing is ok, 9.5 mm drill bit fits fine in the fuel pump along with cam lining up on its mark and notch in flyweel present and acounted for. I took the egr bla k plate off and covered it loosely while it ran with a rag and got showers of what I would say is oil particles, black and slightly thin. I must also admit it did cheap out and got non oe Injectors but I don't think they are the cause. What else could it potentially be apart from component failure (possibly.faulty new parts etc?

Brendan1213 said:

neighbour complained during testing

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What is the world coming to - welcome to the loonyzone and I hope someone can offer some form of solution. Don't forget to post a picture

Did you change the injector pump? This controls the fuelling. If you’ve changed everything else it can’t be anything else common. Does it currently smoke in the same way/manner as before?

300bhp/ton said:

Did you change the injector pump? This controls the fuelling. If you’ve changed everything else it can’t be anything else common. Does it currently smoke in the same way/manner as before?

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Yep smokes exactley the same, how would it be the Injector pump though? Too much fuel not allowing it to burn off?
It smokes more after the first 15 seconds of running.

What colour is the smoke?

Al2O3 said:

What colour is the smoke?

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Greyish, no sweet smell. When I split the exhaust pipe flange I am met with a thick film of gunged up oil. When taking off the exhaust manifold all 4 exhaust ports are covered in oil. Is it possible that the turbo oil drain hose may be blocked causing the oil to push out the seal and into the exhaust?

Brendan1213 said:

Greyish, no sweet smell. When I split the exhaust pipe flange I am met with a thick film of gunged up oil. When taking off the exhaust manifold all 4 exhaust ports are covered in oil. Is it possible that the turbo oil drain hose may be blocked causing the oil to push out the seal and into the exhaust?

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It's not unknown for the plastic plug to be left in the oil outlet hole. In fact, a member of this forum did just that a few weeks ago.

Are you getting oils spatters on the rear window? (James Martin advised check )

Nope no bung left in the turbo (never simple) took inlet manifold and turbo off this morning and all 4 exhaust ports are drowning in oil, its a new head so I thi k I'll have to go back to britpart. Not sure what would have to go wrong for all 4 cyclinders to be burning oil though, had already changed 2 head gaskets thi king that may be the cause.

Brendan1213 said:

Nope no bung left in the turbo (never simple) took inlet manifold and turbo off this morning and all 4 exhaust ports are drowning in oil, its a new head so I thi k I'll have to go back to britpart. Not sure what would have to go wrong for all 4 cyclinders to be burning oil though, had already changed 2 head gaskets thi king that may be the cause.

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You took the inlet manifold off. Was it full of oil?

Al2O3 said:

You took the inlet manifold off. Was it full of oil?

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Yep, ran the engine with the inlet and turbo manifold off to find it smoking bad on cylinder two and a little on one and four. New head it is then. Again!

Brendan1213 said:

Yep, ran the engine with the inlet and turbo manifold off to find it smoking bad on cylinder two and a little on one and four. New head it is then. Again!

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So, it's filling the inlet manifold and the exhaust manifold!

Well wasn't the cylindet head, jesus if I don't fix this soon the wife is going to take away my.bank cards .
So instead of it spitting oil out it could most likely be fuel, so with it being new injectors I can only assume I may be running slightly retarded (checked timing earlier several times before and no fault found) will try advancing slightly but is there any other checks I could do with the fuel system?

Poor atomization and burn of fuel can make sludgey oil-seeming deposits in the exhaust (combination of wetness and soot)

I'd get the injection pump checked as suggested earlier, as you've already changed everything else and the chinesey injectors should give you at least 5-10k miles without trouble

When you check the timing are you eyeballing the woodruff key before checking the groove on the flywheel? Are you also using a locking tool for the flywheel? As I seem to remember there being two grooves on a flywheel of different sizes......