2010 CASE 450 SERIES 3 - Smokes blue, diesel rich under certain conditions. My journey.

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Topper1

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Joined
Feb 19, 2023
Messages
20
2010 450 series 3
3000 hrs
IVECO 445t/M3 engine.
Bosch injection system

No issues on cold starting or full operating RPM under load. Does not use any oil and never has. Oil remains clear for approx 150-200hrs before beginning to show signs of carbonation.

Summer temps above freezing - some smoke on occasion but nothing appreciable,
Typical smoke duringinital start and warm up phase.

My issue appears most notably in the winter and when outside temps drop below 5*C.
Full load - no smoke
Full RPM - Very minor rich diesel smell which clears when under load.
THE ISSUE - After running hard and idling down a few minutes for a 5 minute coffee, she starts to blow blue visually with a very rich diesel odor & burns the eyes.
Upon acceleration, spit n sputter for 10-30 seconds with a noticeable miss, then clears up and runs like a champ.
Treating the diesel with a heavy dose of seafoam seems to clear it, which leads me to believe it is injector related.

As I have just started digging into this, I have yet to:
- test or replace injectors,
-do a compression test,
-perform cylinder leak down test for potential valve issue.
-check turbo & boost pressure.

I'll update as I have more info on my progress.

.
 
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Topper1

Topper1

Member
Joined
Feb 19, 2023
Messages
20
A bit more in-depth then I had envisioned.
The joys of old tech steel lines inside of a tight skid steer frame.
Fuel pump & lines tucked in behind out of sight made for some choice words.
Pulled turbo to intake plenum.
Pulled #3&4 valve covers and then #1 & 2 since I was at it.
Pulled & Tested injectors.

My my. the things we find!!!!! 4 injectors. 3 different brands.
Opening pressures spec 260 bar - 3770 psi
#1- 3760 psi (Bosch #432133761) Good pattern & atomization
#2- 3790 psi (Bosch #432133761) Decent pattern & atomization. Very slight leak by under pressure.
#3-3750 psi (Iveco #112122) Good pattern & atomization
#4-3610 psi (?? # 492J446) Jobber of unknown origin Horrible spray patter. Leaking, very poor atomization..

Replaced all 4 injectors with 4 new Bosch #0 432 133 761 for $820CAD. Should pay themselves off inside of 1 season in fuel savings alone.
****NOTE - Cheap is NOT better when it comes to precision machined & calibrated injectors.****
**** opt for clip style copper washers on the return lines if you can source them. Far too touchy with (2)-5mm copper washers ****

- Compressions - Very happy- #1 445psi, #2 455psi, #3 440psi, #4 430psi
- Leakdown test went well. Cylinder 4 leaked down worse then all the others on the exhaust valve I assume from excess carbon build up from unburned fuel.
I removed the other 2 valve covers & checked valve clearances while covers were off. Very minor adjustments.
- Boost pressure NOT CHECKED as there is no test port, although I may drill one in at a later date and add a permanent boost guage beside my other after market gauge pack. (I've never liked dummy lights)
-Turbo is in good shape with no end play and very minimal oil residue on the intake side.

I will update after our next snowfall event, but as it stands right now, the engine idles noticeably quieter and the exhaust seems to burn a lot cleaner running in the shop.
Just another project where I wish I had one extra elbow on that arm. LOL. Old farts can't bend like that anymore.
CHEERS.
 
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Topper1

Topper1

Member
Joined
Feb 19, 2023
Messages
20
Update.
50 plus hours of heavy snow pushing. The old girl is back to what it should be. Or maybe it's all in my head?? LOL
Noticeably better power, cleaner burning, better fuel economy.
It does still smell like rich diesel after idling down in sub zero temps for an extended period, but not nearly as pronounced as it was.. Very little Blue - eye burning smoke.
It used to act up within a minute or two. Now it's more like 10-15 minutes, which is more likely lower cylinder temps at idle. No longer sputters when throttled back up again.
I'd call it a success.
CHEERS
 
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