2010 MK7 2.2 ENGINE P8FA (PIC HEAVY)

[paul2012]

I currently have in a 2010 mk7 with engine problems. Drives ok, doesn't smoke but engine sounded like a bag of bolts & only done 46,693 miles

Engine out & stripped down to find this.....

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Cylinders 1,2 & 4 are scored. Big end shells starting to strip.

2 options available
1st. See if I can get block rebored for oversize pistons If not.
2nd option, source a another good bare bottom block.

Is it possible the damaged was caused by low oil pressure
Wrong grade of engine oil used

I have no doubt engine would've seized up if continued to be driven.
Anyone have their own theory on what may have caused this engine failure

[karl]

ive done many and they all like that even the 2.4 do it as well

the only theory i have is lack of oil/low oil pressure due to the poor desgin of the oil pump

[andz327]

They can't all be like that or I wouldn't have 280,000 on my 2.2 130, surely poor maintenance and possibly wrong oil getting put in as the oil filters tiny and would clog easy with old thick oil getting pushed through it

[knobby1]

How about a clogged oil pick-up in the sump....??? Possibly a result of poor maintenance-lack of oil/filter changes etc...??

Lord Knobrot

[paul2012]

They can't all be like that or I wouldn't have 280,000 on my 2.2 130, surely poor maintenance and possibly wrong oil getting put in as the oil filters tiny and would clog easy with old thick oil getting pushed through it

How about a clogged oil pick-up in the sump....??? Possibly a result of poor maintenance-lack of oil/filter changes etc...??

Lord Knobrot

According to service history. It's been serviced when due.
Oil pickup was clear, no sludge in bottom of sump.
Pistons rings are not broken.

Only 2 reasons I can think off why this engine failed at 46k. Is either wrong grade of engine oil used or failing oil pump.

[paul2012]

Update.

Bare cylinder block has been dropped off at engine centre for rebore to 0.5 oversize.
They're also supplying me new....

4x oversize pistons with rings etc.
Full top gasket set
Full bottom gasket set.
Head bolts
Mains STD shells
BE STD shells

Price including rebore £540

Will be ready next week then I will rebuild engine.

Not taking a risk with old oil pump. So new one will be fitted.
Haven't decided on timing chain yet. Old one appears to be fine no wear on guides etc.

More pics will follow when I collect cylinder block etc

[bambi mk 1]

Paul get injectors checked Diesel washing the bores and thinning the oil

[Jim Archer]

Looks like it's be driven hard from cold to me.

Is that a hole in a piston in pic 3?

What sort a fit are the gudgeon pins in the pistons?

Been allowed to overheat?

What sort of state is the pump in?

Jim

[andz327]

Only just seen pics, thats fookin nasty, I'm thinking injector problem, it's like the damage on a 2 stroke engine if you dont add 2 stroke oil and just pure fuel, only on this its over fueling and washing oil out the rings and thinning out the oil as well, think you should get crank done though

[dieselhead123]

For the benefit of all who own Mk7 Duratorqs we need to get to the bottom of this 'over fueling' issue.

The injection quantity is determined by injection duration and rail pressure, both of these are controlled by the PCM according to the software installed. So how do these engines 'over fuel'? Does the PCM 'instruct' the injectors to do so?
If the injectors dispense more fuel than the PCM anticipates, (as a result of 'aggressive wear'), then this would lower the rail pressure. Would the PCM not detect this and log a fault? It does when the rail pressure drops as a result of excessive leak-off.
Far more questions than answers I am afraid.

In the meantime, repairers such as Karl, Bambi, Paul and ourselves will continue to make a living repairing these engines, at the expense of their owners and Ford's reputation.

TIM

[bambi mk 1]

For the benefit of all who own Mk7 Duratorqs we need to get to the bottom of this 'over fueling' issue.

The injection quantity is determined by injection duration and rail pressure, both of these are controlled by the PCM according to the software installed. So how do these engines 'over fuel'? Does the PCM 'instruct' the injectors to do so?
If the injectors dispense more fuel than the PCM anticipates, (as a result of 'aggressive wear'), then this would lower the rail pressure. Would the PCM not detect this and log a fault? It does when the rail pressure drops as a result of excessive leak-off.
Far more questions than answers I am afraid.

In the meantime, repairers such as Karl, Bambi, Paul and ourselves will continue to make a living repairing these engines, at the expense of their owners and Ford's reputation.

TIM

Tim I made my money repairing Yorks,its just a pastime now .I wish

[dieselhead123]

Tim I made my money repairing Yorks,its just a pastime now .I wish

Bambi, I made my money pushing Yorks

TIM

[bambi mk 1]

Tim I made my money repairing Yorks,its just a pastime now .I wish

Bambi, I made my money pushing Yorks

TIM

You must have been right fit in your younger days Tim Bump started a 2417 D Series on my own once It was on the flat and wraped my arms round the front wheel got it rolling jumped in and she fired up Think I would burst if I tried that now

[paul2012]

I didn't want to use worn out/faulty injectors in a newly rebuilt engine.
Injectors were sent away last week & came back clean bill of health.

Engine hasn't suffered from overheating issues & not low on engine oil.

So over fuelling is not the cause.
With over fuelling results in burnt /melted pistons crown & end up being holed

As you can see below these pistons show no signs of over fuelling.




Main damage is on one face of piston skirts shown below.



Piston Nural 8650A



Measurements for these pistons are as follows

Piston diameter 86
Piston length 69.8
Gudgeon pin diameter 30
Gudgeon pin Length 67
Bowl recess depth 15.8
Bowl recess diameter 46.9

Nural have a diesel component trouble tracing chart.

On there it clearing points out problem this engine had. (high lighted in blue box)
Cause A: Damaged concentrated on one face - Lack of lubrication.

pist diag.jpg

With BE & mains shells also starting to strip. Clear signs of lack of lubrication.

As Karl posted previously he has done many engines including 2.4's that have down the same.
His theory was lack of oil / low oil pressure.

With all of the above. It's the only thing it can be. A failing oil pump causing premature engine failure at 46K
Of which I originally suspected.

[BHM]

Good morning Paul,
are you going to strip the pump to see reason of failure?

BHM