Diesel leaking in engine
Hello!
Car model: V40 D3 2016, engine: D4204T.
I attempted to replace the intake manifold because the old one was heavily clogged with soot. I ordered a replacement manifold for around $600 and followed the procedure shown in This video. The whole job took me probably around 8 hours.
To remove the intake manifold, I had to disconnect one high-pressure fuel line and two rubber fuel lines. I managed to remove the old manifold and install the new one, but I immediately noticed that the threads on the new manifold were extremely tight. Reinstalling the old throttle body required much more torque than expected, and several of the other bolts were also unusually difficult to thread in.
There is one step I am especially uncertain about: the throttle flap actuator arm installation.
My understanding was that the actuator pin should align with the hole in the intake manifold shaft lever. However, this was very difficult because the resting position of the new manifold flap mechanism sat slightly lower than on the old manifold. That meant the fully open position on the new manifold was also slightly lower compared to the original one.
To make it fit, I positioned the actuator at what matched the old manifold’s highest position, but not the new one. I then used a string to pull the actuator pin slightly lower so I could insert it into place. I am honestly not even sure if I aligned it correctly.
Now that when i start the car I get error code it says air intake low, engine performance bad, etc. And the engine was flooding with diesel. What could have gone wrong. Every screw etc is placed correct. I did not damage anything when removing or inserting the manifold.
Help would be really appreciated!
BR