5,000 km and dead

[macca]

The problem will be proof of what happened and why, that has to be understandable and rock solid with clear cut processes leading to the outcome.
Any questions or variables to the evidence offered and your case is cut off at the knees.
It could have been this or that and there goes your case.

Years ago I had a Ford diesel work van that a local dealer reconditioned the motor, it failed and it turned out to be a broken bottom ring.
At the time Ford had lifetime warrantee on their repairs but the fine print said it only covered lubricated parts.
Ford said a ring was not lubricated!
The head of mechanics at our local TAFE was an acquaintance, I spoke to him about it.
He wrote a letter quoting Fords own training manuals how a bottom ring picks up oil, lubricates the bore and scavenges the oil off the bore during the pistons travel.
Ford could not dispute it was in fact covered in oil to do its job therefore lubricated and approved payment.
I could not have done that on my own.

Get your ducks in a row and if you are in the right you may well be reimbursed, good luck mate.

[Cuppa]

At the very least I think you should expect Brunswick to put in writing to you what they believe occurred, & what they believe to be the cause & why they think it is not covered by their warranty. Real words not 'whitewash words'.

If they are not prepared to do this in good faith then it is a very poor look for Brunswick & a warning to potential future customers.

[mudnut]

What was the original warranty for the reco?

[rainsey]

Sorry, not defending them but they do state ( i think ) 3 months or 5000 km on second hand ZD30 engines.

Unless they rip them open and refurb the engine, it would be pretty hard to qualify the status of the engine. Again, not defending BD but the engines they have are coming out of customers who have done V8 upgrades. They have no idea what the engine has been through.

Its sort of a lottery with second hand engines. Would I be pissed off, yes, could I blame them, probably not.

Kindest Regards

Rainsey.





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[rainsey]

Sorry, forgot to mention, flame suit is on



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[Cuppa]

Ah, I mistakenly thought the motor was a Brunswick rebuild. I didn’t realise it was just a second hand motor. It does rather muddy the waters so my previous post should be discounted. We all take a punt on secondhand motors.

[rainsey]

Ah, I mistakenly thought the motor was a Brunswick rebuild. I didn’t realise it was just a second hand motor. It does rather muddy the waters so my previous post should be discounted. We all take a punt on secondhand motors.

Im only guessing at a second hand motor. Didn't not think Brunswick refurb'd ZD30's.



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[Rumcajs]

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.

Over-boosting to 25 psi shouldn't cause what happened, someone is pulling your leg. They're not being honest and I'm sure that they're just covering up their arses telling you a tall tale so you cough up for the repair. ZD30 over-boosting is also well know phenomenon and engine control system has a built in protection meaning limp where you loose accelerator pedal and boost is limited to 10 psi until you reset (releasing pedal). For the control system not knowing the MAF would have to be really faulty as on GU series 4 the limps occur very quickly indeed once your boost goes past 18 psi and you keep going it will limp or fuel cut.

What they sold you is a second hand ZD30 motor with questionable history. BTW ZD30 Di never ever loose bottom end, that is built like a tank, it is the top end which is weak and if it was just a head gasket they wouldn't be pulling motor out. Ask them to show you the head gasket...although they will probably wiggle out of that one too.

What probably happened is that one of the pistons burned the hole in them which is not over-boosting but over-fuelling, that happens without warning or preceding symptoms and yes engine is usually running rough and or can be driven if the hole or crack is not extreme. The pistons are the weakest link in the whole scenario.

Fitting Dawes valve and blocking EGR is not a fix alone. Indeed I recommend Tillix valve instead ( it doesn't suffer from boost bounce effect as much) and also a needle valve to control turbo spool up time.

Do you have boost and EGT gauges installed? Lugging that motor in 5th gear or overdrive full throttle pedal will see EGTs going to 500°C + and starting to slowly ruining the pistons consequentially/incrementally.....

Did you know that glow plugs system contributes greatly to these motors failing? Having 5 mins glow time after engine is running is utter lunacy!

Indeed,modding glow circuit to reduce/limit glow time is a must.

Consider installing catch can as well.

In the end any ZD30 which did not have all the mods done prior being fired up for the first time is just a grenade set to go off once the circumstances align right.
Regards

[the godfather]

Wow, so many questions.
Okay Brunswick have given me a comprehensive list of the work done, including costs. All up cost came to 7k.
The warranty was for 3 months or 10,000km, and excludes labour. This is in the terms and conditions.
They have offered me the part that have been taken off to inspect when I pick up the car. Or course who knows if they where mine or not?
Yes I have a boost and EGT gauge.
No they haven't really offered a reason as to why it happened other than over boost. According to my guage it hit 28PSI. The gauge lists the past highest spike.
Dawes valve is fitted and currently set to 14PSI (this is what they recommend).
EGR is blocked.
No catch can yet.
Warrant given on the repairs is 6 month or 10,ooo km.

Am I happy with the cost? No, of course not.
Will I be happy to get it back? Yes. I love that vehicle. Despite this it has served me well.

In regards to Civil action: anything that isnt criminal is civil action. So I would need to pursue it myself. I am fine with that....except, small claims opt out at $2,000, so the cost would be mine. Legal proceeding will be around $5,000...So no real point of throwing money away.

The real question is: Do I keep it?

[Rumcajs]

Honestly for 7 grand or around there you could get Nissan brand new long motor (no IP pump or turbo), anyway can I ask why you had the engine replaced with Brunswick sourced unit in the first place?

To ponder whether to keep it or not is a dilemma I'd personally not wanting to face either. At the end of the day it depends how much do you want to sink to this venture because something tells me it ain't over yet. First instinct would be to cut the loses and be done.

Look I hate mine as a daily driver full stop. Under powered fuel guzzling slow behemoth which needs to be handled with care otherwise it breaks but I do love it in off road scenarios though, but question of reliability is always not far from my mind when going off beaten track.....

Regards