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[dave the builder]

you could temporarily blank the EGR to test drive,rule that out 

Don't discount the EGR, sounds very similar symptoms to what ours had. Cleaned it (fully - solenoid as well) a few times but it still failed eventually, new one was the only answer and I was lucky to win a new genuine one on eBay for less than half the price of a dealer supplied one.

Ours did raise EGR codes though along with complete lack of power which required code reset to make it driveable again! Also cleaning the boost valve (one torx) is a worthwhile excercise.

Yep, one of my thoughts too 

also a dirty MAF has similar symptoms 

[JamesV6CDX]

Bit disheartened. I have a niggling thought that - it the compression on No4 maybe not high enough, and that's why it's not running great.

I might order a diesel compression tester, be good to have one anyway!

[JamesV6CDX]

I'll get an EGR blank anyway.

I also wonder if the cat is a bit blocked. Look at the state the DPF was in, the amount of shit going through the exhaust before the repair was hideous...

[dave the builder]

Bit disheartened. I have a niggling thought that - it the compression on No4 maybe not high enough, and that's why it's not running great.

did you check the ring gap on 4 with new piston and rings ?
you ground the valves ,so compression should not be an issue 

it's not unusual to have a few niggles ,don't be disheartened ,you'll sort it 

[Marks DTM Calib]

It wont be EGR, they cant cause a miss fire on a diesel, just a lack of boost.

Injectors are a favourite, second hand ones are a waste of money to be honest as you have absolutely no idea what condition or mileage they are.

And a single injector can cause a very random set of results, if they leak they lower the rail pressure and impact the other potentially good ones.

Injectors also need to be coded to work properly, the parameters set the time to open, time to close, flow rate etc

As for the 'tool' try selecting an alternative car line which had that engine (it went in the Mokka, Meriva, Corsa, Astra etc etc)

[JamesV6CDX]

It wont be EGR, they cant cause a miss fire on a diesel, just a lack of boost.

Injectors are a favourite, second hand ones are a waste of money to be honest as you have absolutely no idea what condition or mileage they are.

And a single injector can cause a very random set of results, if they leak they lower the rail pressure and impact the other potentially good ones.

Injectors also need to be coded to work properly, the parameters set the time to open, time to close, flow rate etc

As for the 'tool' try selecting an alternative car line which had that engine (it went in the Mokka, Meriva, Corsa, Astra etc etc)

Thanks, Mark

Just because it's the most inexpensive, quick and easy option, I dropped it at my local independent garage tonight. I usually only ever go there for MOT, but, the chap that recently took the business over, who I think is about my age, always talks to me at length about my Omega stuff and is genuinely interested at the projects I take on.  He seems knowledgeable and honest and passionate about cars, so I thought why not.

I had a chat with him about what I've done with this one, and showed him some of the pictures, such as the piston, and valve lapping.

He is going to see if their kit will do the injector codes tomorrow, and if so, he's going to make sure all 4 injectors are correctly coded.

Nothing to lose, and I don't feel like they'd try and rip me off. based on the fact I showed them pictures of me taking the engine into a million parts!

I should add - that fuel starvation symptom I described, I think was actually fuel starvation  The car was on the red, and at the point it lost all power, was grumbling something about "fill me up" 

I filled her to the brim with V power, and used her for work today. Now not missing a beat, and seemingly not really hesitating, or smoking. Just very "diesely" now.

[JamesV6CDX]

Back from the garage. It's not fixed it, but in fairness may have given me something to go on.

The chap said to me "I was able to programme in the code from the top of each injector, but it wouldn't let me do the small adjustment process afterwards, because it says the fuel temperature sensor is out of range". He said to sort out that fault, and bring it back.

So it looks like the injectors are now coded, at least.

No difference in running, still very clattery and diesely.

Interestingly, the EML was not on when I dropped it off, and has never been on, but, it was on when I collected the car. My ODB2 hand held is saying no codes, despite the light being still on - so I will connect up the tool that must not be named shortly, and see what that has to say.

I would have thought if  I'd have missed a fuel temp sensor on the rebuild, it would have thrown a light before now? Does anyone know where it is, on this engine? I can't see anything obvious on / around the rail, etc, apart from the big plug in the end of it, which I'm guessing is rail pressure?

[Doctor Gollum]

Might be near the filter

[JamesV6CDX]

Might be near the filter

I've had a look for the part online - there's seemingly no such thing. I wonder if it's built into the pressure sensor.

I'll see what the kit says shortly - decided to chill out for an hour and have a fry up, first 

[STEMO]

Might be near the filter

I've had a look for the part online - there's seemingly no such thing. I wonder if it's built into the pressure sensor.

I'll see what the kit says shortly - decided to chill out for an hour and have a fry up, first 

Fry up! You bastard 🥓🍳🍅 starving here 

[Doctor Gollum]

Might be near the filter

I've had a look for the part online - there's seemingly no such thing. I wonder if it's built into the pressure sensor.

I'll see what the kit says shortly - decided to chill out for an hour and have a fry up, first 

How many wires to the sensor on the fuel rail?

[JamesV6CDX]

Might be near the filter

I've had a look for the part online - there's seemingly no such thing. I wonder if it's built into the pressure sensor.

I'll see what the kit says shortly - decided to chill out for an hour and have a fry up, first 

Fry up! You bastard 🥓🍳🍅 starving here 

Danish bacon, chiploata sausages, fried eggs, beans, tomatoes, hash browns, toast and butter, and a nice cuppa tea 

[Doctor Gollum]

Well, there's no point having a crap cup of tea

[STEMO]

Might be near the filter

I've had a look for the part online - there's seemingly no such thing. I wonder if it's built into the pressure sensor.

I'll see what the kit says shortly - decided to chill out for an hour and have a fry up, first 

Fry up! You bastard 🥓🍳🍅 starving here 

Danish bacon, chiploata sausages, fried eggs, beans, tomatoes, hash browns, toast and butter, and a nice cuppa tea 

Hope yer fickin astra explodes! 

[JamesV6CDX]

Might be near the filter

I've had a look for the part online - there's seemingly no such thing. I wonder if it's built into the pressure sensor.

I'll see what the kit says shortly - decided to chill out for an hour and have a fry up, first 

Fry up! You bastard 🥓🍳🍅 starving here 

Danish bacon, chiploata sausages, fried eggs, beans, tomatoes, hash browns, toast and butter, and a nice cuppa tea 

Hope yer fickin astra explodes! 

It'll be more likely my guts that explode, they seem incapable of processing that much fatty food in one go, I'll give it an hour until I'm legging it upstairs, tops. Worth it, though