and another rebuild

[Rumble bee]

Sounds like a donkey having a fit now

[martynx]

I wouldn't ignore a thread like this Guys, it was pointed out to me only this evening!

I spend all day every day either tuning or repairing Transits, I am very careful in the way I work & repair wise , i see countless vans idling poor, cutting out, knocking , down on power etc & apart from making them run right, i believe getting them running well, with latest software , new fuel valves etc reduces the possibility of holing a piston.

The failure rate on engines that i have tuned is so small that I don't believe the tuning itself causes it as plenty of these engines fail in stock form, the vast majority I'm sure

I simply couldn't do what i do if i didn't believe it was largely safe.. any extra stress from strong tuning or hard driving will expose a mechanical weakness though & the wrong piston size fitted prior to failure is must be pretty fundamental to this case i think?.

The fact that wrong correction factors were wrongly programmed is a shock to me as was the failure itself, I would never routinely skip this important part then remap it as I have never had any interest in doing anything other than a thorough & as perfect as possible job.. & I recall asking Rumble if he had made a note of the codes prior to me programming them as they are tricky to read so completely puzzled by that part .. The factors for sure are crucial to quiet running & good idle but could wrong ones lead to a piston failure ?

Pistons - I thought up to recently that all 2.2 short block were the same.. not the case , 110 & above have a different piston, so with Rumbles being a 110 Ex AA ( & now running 115 software ) its got the right pistons for the 140 injectors right ? Although if ford supply a re-manufactured engine for any 2.2 only one part number is given, suggesting that one piston now fits all ?

I have been recommending fitting these "high flow " 140 injectors for some time now to 85/110's & have a done the conversion myself a few times & tuned afterwards using the same software as used in Rumbles so don't see a problem - if it was for example an 85 with the different piston crown receiving them, yes the combustion event will differ as it happens in that crown in the main but You can’t say its absolutely detrimentally otherwise they wouldn't run as well as they do & the others would have failed by now & Ford wouldn't have standardised one of their complete replacement engine offerings - & Ford may have used a different piston for higher power 2.2's but its these models that historically have failed more isn't it ?

As for Rumbles van itself, it wasn't running right, & was smoking excessively ( if i recall correctly ) & he fancied retuning it - I recommended new injectors based on the symptoms described prior to retuning, only other option is testing the originals but that's a week without the van so not ideal.. So this was as much a repair as a tune with the added safety factor of using new injectors. After all work was done with pump & pilot passed after 2nd go , it didn't sound 100% perfect but i couldn't put my finger on it beyond that.

For it to fail so quickly after this work that attempted to get it running right is a surprise to say the least & of course anyone would think to question the last person who worked on it ..
Looking at the tune that was installed originally mine wasn't any more extreme in terms of the target power( 140ps/345n) & countless vans ( 115's ) that have come to me for tuning run this software with only very slight differences that each van requires..
It came back for 2nd BCM reprog yes , Rumbles was the original bitch of a job BCM wise as Loot found out before me ! ,the file size changed & ford supplied files had a VIN HEX error – But the injection correction factors are in the PCM (at address D0200) so I am still at a loss to see how I that issue came about .

[kulataz]

I just wanted to add that my standard 130ps 2.2 did exactly the same to no2 piston which cost me a lot of money. It had nothing to do with any remap as it never had one. i have seen loads of threads on the 2.2 melting or cracking pistons, in fact when I took my injectors to a specialist to check they had one identical blown. At the time I was looking at getting the bore sleeved and a new piston but Ford(much to the surprise of the parts guy) were selling short motors inc pistons, crank and block, ready to bolt in for £750 +vat. I bought one immediately and actually got it for £500+vat so they must know there is an issue to have reduced it so much

This was three years ago now.

Graham

[rhubarb]

I think basically the problem is that these common rail dervs are too highly strung...And most are driven hard and a lot are neglected..=..Recipe for disaster.

[kulataz]

i dont fully agree with you here, i do feel there is an issue with the engine somewhere but the similar engine in a Mondeo doesnt seem to suffer. theres something specific to a Transit doing it. My van is privately owned and was not thrashed or driven hard as I carry my kids and dogs in it.

Regards

Graham

[rhubarb]

i dont fully agree with you here, i do feel there is an issue with the engine somewhere but the similar engine in a Mondeo doesnt seem to suffer. theres something specific to a Transit doing it. My van is privately owned and was not thrashed or driven hard as I carry my kids and dogs in it.

Regards

Graham

Mondeo TDCI's are an utter timebomb...Be easier to write down what doesn't fail on them.

The Transit engine will be under more strain in a van considering it's use and it's weight..

Just have a look on ebay for how many are for sale for spares or repair..

[paul2012]

Regarding holed/melted pistons.
As for engine internals (crank, rods, bearings, pistons etc)

They are all the same for 110, 115, 130/140ps engines apart from 85ps (less DPF)

According to Ford & are supplied that way

Engine part no 9C1Q-6006-AA

Pistons to be holed/melted & an issue which also effects engines running standard factory map/calibration

A remap alone wouldn't be the cause....

[paul2012]

Great work with the rebuilt

[karl]

Regarding holed/melted pistons.
As for engine internals (crank, rods, bearings, pistons etc)

They are all the same for 110, 115, 130/140ps engines apart from 85ps (less DPF)

According to Ford & are supplied that way

Engine part no 9C1Q-6006-AA

Pistons to be holed/melted & an issue which also effects engines running standard factory map/calibration

A remap alone wouldn't be the cause....

the 85ps still uses the same crank and conrods the same as the 2.4 tdci just differnt piston sizes

anyway its all in the thread

[Altransit]

Locked at the request of Karl.

[ake]

Thread thinned out at Karl's request