Holden Commercial Range

Any excess smoke from a diesel engine can mean a too-rich mixture. So are you certain the injectors are the correct ones for that engine? Has a sensor been bumped during the replacement process that is not sending the right signal to the computer that controls the injection on a modern turbo-diesel?

Also, cold-start problems in an engine like this are often traced to the glow-plugs. These are crucial to warming up the cold engine internals so that combustion will take place. So perhaps a check of the glow-plug wiring is in order as this could have been disturbed while the injectors were being replaced.

Has anything else been changed or replaced as part of this process? Has the engine been sitting for an extended time (allowing the fuel to go stale)?

The reason you can’t start the engine in second gear is for safety reasons. Car makers fit what’s called a Neutral or Park switch, which means the engine won’t crank unless the car is in Neutral or Park. That prevents the car starting in gear and taking off.

If the lever’s connection to the transmission has failed or become excessively worn, you can get the symptoms you have because the lever won’t select Neutral or Park. And therefore the engine won’t start.

However, it’s highly questionable that this is connected to the limp-home mode. That’s usually caused by a problem with the driveline that threatens to do more damage if you continue driving. The gear lever problem sounds more like a simple mechanical issue. Did both things happen at the same time? If not, they’re very probably not related.

Those codes are reasonably common ones. The first two (0193 and 0089) generally relate to a problem with the fuel rail, specifically the pressure in that rail. This is obviously critical to how the engine runs.

The third code (0401) is more commonly associated with the flow of the EGR valve. If this valve is damaged or blocked, then this fault code would likely show up. As such, you may find you have two separate problems, rather than a single one.

Low pressure in the fuel rail would certainly explain why the performance is off, and the overheating could easily be associated with an EGR valve failure. A blocked EGR can raise combustion chamber temperatures while a failed EGR can actually leak coolant and allow the engine to overheat that way.