5,000 km and dead

Okay, question time. My 5,000 km old engine has failed me. Please note this isn't a wing about the mechanic at all. They are ha[[y tp sort it for me, but I currently don't have the funds to freight it to them.
Symptoms:
Boost spiked to 25 PSI and started running rough.
I limped it back to the office with no more spiking, just running rough. Was only about 3km away.
Very hard to start
When it does start it spit black smoke and moisture out the back end.
Scan gauge says there is no errors and everything is normal, so I got the local guy to come and scan with his gauge, still says no errors.
I also notice the coolant was low, though I expected that after 5,000 km from fitment.


Any ideas?
Cheers
The CynicalGrump The Godfather.

Can the Engine builder give you a guide on tests to run prior to pulling it out mate? I'd have thought a compression check would be a start.

Good luck mate.

Bugger!!!

Check oil level, oil colour?

G'day GF,
Total long shot, and I'm definitely no mechanic!
Yours being a 6.5 I believe? is there any chance WA was hot on last Saturday and the PMD overheated mate ?
Cheers MB

Sorry, it is a ZD3.0 (206 model Di)
I changed the oil it was fine, no water, no crap etc.
I wont be pulling it out. Brunswick fitted it. They aren't running from it either. I told them I would scan 1st in case it is something simple.
Would the MAF cause this?

G'day GF,
Apologies mate, outa my league!
Cheers MB!

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Originally Posted by the godfather

I also notice the coolant was low, though I expected that after 5,000 km from fitment.
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How low?!
Why do you expect coolant to be low after driving just 5000km from fitment?!!

Hopefully the missing coolant is because the cooling system may not have been burped properly.

Cracked #4 piston maybe ?

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Originally Posted by Sir Roofy

Cracked #4 piston maybe ?

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I would think if that was the case it wouldn't run at all. But i haven't tried to drive a car with a busted piston.... As others have said. How low is the coolant. If the radiator was pretty much dry, this maybe a concern, head gasket or cracked head. Clean the MAF and see if this changes how the engine reacts. Sometimes the MAF can go and just create poor performance and not bring up any codes. I've had this before. Sometimes they just die totally and the car is undriveable. Always good to keep a spare maf in the glovebox for these motors.

Good luck.

Coolant took about 1 - 1.5 liters. I assumed the system hadn't been burped properly to start.

Just re-read this again still think its a crack
could be the MAF must be really choked up
if it is the maf

Quote:

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Originally Posted by Sir Roofy

Just re-read this again still think its a crack
could be the MAF must be really choked up
if it is the maf

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Hope your wrong Roofy.

Sent from my GT-N7105T using Tapatalk

Well it isn't the MAF as I put a new one in this afternoon and it made absolutely no difference. Old one was pretty dam clean I might say.
Looks like its going back to Brunswick's on the weekend.
Fingers crossed there wont be an argument over warranty.

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Originally Posted by mudski

Hope your wrong Roofy.

Sent from my GT-N7105T using Tapatalk

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So do I mate but that is how my exhaust was like in the end

Yeah but was it 5,000km old?

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Originally Posted by the godfather

Yeah but was it 5,000km old?

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No it wasn't but there was no indication that anything was wrong
just let go
hope I'm wrong and you get an easy fix

Quote:

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Originally Posted by Sir Roofy

No it wasn't but there was no indication that anything was wrong
just let go
hope I'm wrong and you get an easy fix

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I am starting to think you are right. Either way, the engine is still under warranty. I just hope there is no argument.

Just put a coupla nissanpatrol.com.au stickers on it... ...might make them more reluctant to argue???

Ok I'm outta my league here to, haven't had it happen to me..

But i remeber reading (I think) that the crank angle sensor on the front of the engine can cause what your describing.
Sorta makes sence, if your ecu can determine crank angle then timing will be shot.

I had a bit more of a look today and noticed a fair amount of oil over the top rear of the motor where the red arrow is. Well enough for it to be dripping down the motor.

Attachment 69546

Quote:

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Originally Posted by mudnut

Hopefully the missing coolant is because the cooling system may not have been burped properly.

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That can't be a good thing. Air bubbles circulating and possibly getting stuck in the alloy head water jackets won't produce good results if it goes that way for too long.

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Originally Posted by the godfather

I had a bit more of a look today and noticed a fair amount of oil over the top rear of the motor where the red arrow is. Well enough for it to be dripping down the motor.

Attachment 69546

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That could be an glow plug seal leaking. (Or is it the injector??)
They are a one use thing only so if the old ones have been reused, or even old ones installed roughly you'll get oil spilling up out of the rocker cover.

Do you have a catch can?

If not pull the turbo to IC hose off and check the amount of oil in there.

Well, she has gone back to Brunswick Diesel now.

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Originally Posted by the godfather

Well, she has gone back to Brunswick Diesel now.

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Hope it's a easy fix

I hope its a free fix. Already got slugged 8.5k to put the motor in in the first place. Can't really afford another hit. To make it worse my job depends on my car working.

Quote:

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Originally Posted by the godfather

I hope its a free fix. Already got slugged 8.5k to put the motor in in the first place. Can't really afford another hit. To make it worse my job depends on my car working.

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Spending that sort of money to build a good rig and ending up with mechanical(or electrical issues) is definitely not good.
I've been wondering. You live in WA. Brunswick Diesel is in WA. Why is it expensive to ship it to them?
Even RACV roadside care equivalent in WA should've been able to take care of that for a little cost, if not for free.

Coupla hundred km (give or take) Perth to Brunswick @dom14!!!

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Originally Posted by UncleFrosty

Coupla hundred km (give or take) Perth to Brunswick @dom14!!!

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165 kilometers, but close to Bunbury so there should be plenty of couriers and trucks on that rout.

Ended up costing me 380 to get it there. Original quote was 650.
An to add to that, I am a sales rep on commission. So I am broke at the moment.
On the up side work lent me an SS Ute with a 350 Chev in it :bananadancing:

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Originally Posted by UncleFrosty

Coupla hundred km (give or take) Perth to Brunswick @dom14!!!

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In Victoria, RACV Total care covers 100km towing and even more in country areas. I reckon with such a deal, you can pretty much cover the most cost of towing if not all.

Quote:

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Originally Posted by the godfather

Ended up costing me 380 to get it there. Original quote was 650.
An to add to that, I am a sales rep on commission. So I am broke at the moment.
On the up side work lent me an SS Ute with a 350 Chev in it :bananadancing:

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Get a roadside assitance deal with an RACV equivalent in WA. It's money well spent, especially in 4WD'ing.

lets hope they get it sorted and don't try and charge you for it mate......... if it's something they did or didn't do, then I'd be asking for the freight money back too

Okay, I have had an update from Brunswick on my motor.
For some reason (Unknown) the engine has over boosted.
Not cause by the MAF.
This has cause the head gasket to blow between two cylinders.
Bottom end is fine, nothing wrong down there.
So the engine is coming out, head getting faced or replaced.
Dawes valve getting fitted, and EGR getting blocked.
Is this warranty?
Yes and no.
Worst case scenario is 5k, which Brunswick are willing to split 50/50 with me. So 2.5k my cost.

Good news that its recoverable mate. About the 50/50 bit hmmm! i don't know what discussions were held between you and Brunswck re the original motor, but seems a of a short life for a recon motor. Not knowing the full story it's hard to tell if its fare or not, but hopefully Brunswick realise that a lot of people read these forums and will have a think if they have a similar problem. I have always said that it is not only how good a job a company does, its how they react when it all turns to crap. In my own engineering business I have had to bite the bullet a couple of times when things went south and we couldn't identify a customer/operator error. I have to say that only happend twice in 25 years operating, but never the less i coughed up and fixed things at no cost to the customer other than freight.
Just my opinion.

I am sure I will be discussing more when it come time.

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Originally Posted by the godfather

I am sure I will be discussing more when it come time.

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Discuss it beforehand. If there's no operator error(as 4bye4 explained above) the right thing for the repairer is to fix it at no cost.
It's still gonna cost you anyway. The transport cost, time, the hassle of having to deal with the failure of newly reconditioned engine's failure, loss of work due to that, etc etc is costing you. If the "boost spiking" has nothing to do with the work they did on the engine, then they need to be able to explain it that it's not their fault.

Quote:

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Originally Posted by the godfather

Okay, I have had an update from Brunswick on my motor.
For some reason (Unknown) the engine has over boosted.
Not cause by the MAF.
This has cause the head gasket to blow between two cylinders.
Bottom end is fine, nothing wrong down there.
So the engine is coming out, head getting faced or replaced.
Dawes valve getting fitted, and EGR getting blocked.
Is this warranty?
Yes and no.
Worst case scenario is 5k, which Brunswick are willing to split 50/50 with me. So 2.5k my cost.

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Onus is on the repairer to ensure boost related components are finely tuned and checked, so the newly reconditioned engine doesn't end up getting blown less than 5000km after the job, and end up going back to them with more headaches. Repairer/mechanic is the expert, not you.
So, based on the information given, it is a warranty issue, 'cos the part that is blown is a part they repaired.(Newly installed head or head gasket blows & no recognizable operator error was discovered)
If you've had discussed to cut corners with the repairer during the engine rebuild job, then the warranty conditions were compromised. Something like that happened to me while ago, where I cut corners by not pressure testing a cylinder head with a head rebuilder & he managed to miss a visually obvious crack by missing to repair the crack. Head rebuilder was happy to repair the crack again and resurface the head for me in my case, 'cos it was visually obvious crack(the excuse of no pressure test was done wasn't a strong argument in that case). The downside for me was the head getting machined again meant the combustion chamber compression going tad higher than for my liking. I decided not to resurface the head & opted for an off the shelf chemical solution, 'cos I believed the crack wasn't that deep. The head is still going good after four and half years, and I learnt my lesson not to cut corners with important things, even when the finances are tough.

Any news on this? @the godfather

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Originally Posted by 4bye4

Any news on this? @the godfather

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Mo mews. No resolution yet really.
I spoke tot hem mid week and they said 3 weeks before I see it again :(