Hi all

My friend has a transit 2.4 tdci h9fa engine with problems.

Parts changed

Oil cooler, oil pump, tappets,  flywheel, cam sensor, crank sensor, 10 STARTER MOTORS, fuel filter, both sensors in the fuel pump, various gaskets

Bought as running but smokes, get on the motorway and engine conks out. Had a quick check couldn't see out obvious so towed him down the motorway as we was 10 mile from home and the police pull me and take us to an inspection yard. Never mentioned that it was illegal or anything wrong with towing on a motorway but my friend had the wrong insurance for the transit So they siezed it.

When we got it out of the compound and £400 lighter it started drove for 5 minutes and it conked out again had a good look at it and oil was a bit emulsified. Took the sump plug out and 2 litres of water came out before any oil. Got it recovered home and started investigating.

Turned out the oil cooler had gone so full engine was full of sludge. Stripped it all down and replaced oil pump, oil cooler and tappets and rebuilt. 

Flushed engine with oil when drained was clear of water filed the fuel filter up got the fuel up and it fired and ran lumpy but still ran.

Next day it started but still lumpy.

I did leak off test that was fine only code on diagnostics was dome light.

Now the frustrating part now it don't fire we keep at it and just as it it about to fire the starter burns out.

10 starters later and 12 months still the same either starter burns out or battery goes flat

I have been a mechanic for 24 years and this is the only vehicle I cant get running either I'm being really thick and missing something really obvious or the van is cursed thanks for your time reading this. 

 

 

 

Hi...you wrote "my friend' Bought as running but smokes, get on the motorway and engine conks out.

It likely smoked and conked-out through crancase dilution and pressure. The emulsification indicated that.

Did no one 'check'the oil before even driving the car?

You'd know it is unlawful to flat tow a car on a motorway.

 

Pretty well none of the parts replacedwould have anything to do with the problem. If you have fuel, spark and

compression at the cylinder head  the car has most of what is needed to start. In between them is an ECU

and a few sensors. You have to check fuel pressure and volume..and why emulsification. Likely is a cracked

head, block blown gasket or someone didn't like the owner.

 

You have not said how well it runs when it runs. My opinion when...and I see it even with Holdens with the 

run then  die problem...people changing "everything"...including sensors which are rarely the issue. Crook

spark plugs can be. Blown had block or gasket will be...Sludge in the camshaft activators is. Sludge in hoses

is.

 

I realise you said you are a mechanic but burning out starters is not the actions of competence. They draw

hundreds of amps in some cases....half a dozen cranks is enough...stop and let cool. As an auto electrician

old school I was taken aback at up to 10 starter motors burned out by a mechanic presumably through

relentless cranking.

 

You have rebuilt the motor it seems...to some degree...did you compression-test before and afterwards?...

withall plugs out and wittout cranking the starter to fusion point...? four cranks should do each cylinder.

ifslower than that youlikely have worn bore or rings or broken rings.

 

Did you check that the (oil deprived) cam lobes are ok?

 

Did you wire-brush out every oil gallery and replace all gallery plugs correctly. I doubt you went as far as

a proper job on the activities so far.

 

Next...check all manifold hoses for sludge...check fuel pressure, injector(?) cleanliness and firing...using 

correct devices, I don'tknow the engine so presuming injection...check timing is correct.

 

Was it worth the fine?...or better just left with the police...I wonder.

 

That's all. My regards

 

 

 

Hi pythagorus

First of all its diesel so no spark plugs 

The engine has been fully stripped down to the block  cleaned and is sludge free 

The timing is set

Fuel pressure is OK

Emulsion due to oil cooler leaking internally mixing oil with water

all ecu wires traced and pin outs checked

Starters was all cooled and sometimes didn't even get half a dozen cranks before it smoked out

There is good compression on all cylinders

and we didn't get a fine or any repercussions for towing on the motorway the fine was for no insurance. The officer had to check with his colleagues as he didn't know and it was legal to tow on a motorway as it broke down on the motorway.