Engine Replacement

[transitman1]

Hi guys its my first post on here so I hope it makes sense

My Father has a ford transit 02 reg T260 SWB with a 1.9 disel dura-torq engine which has covered about 160,000 miles. About 3 weeks ago some sort of bio-fuel was put into it (wasn't me) and the van started to play up, eventually the van lost most of it's power and went into limp mode and just crawled along. With my limited mechanical knowledge I have cleaned out the fuel tank e.t.c and have flushed the fuel system with various treatments & replaced the fuel filter. The fuel is getting to the injectors, however the van will now not start, it tries to tick over but doesn't start. We've had some people look at it and they have said that the engine is probably knackered / broke. I don't want to spend an absolute fortune on people trying to find out whats wrong with it so was thinking about getting a new engine in it. Would anyone be able to point me in the right direction of what engine I should be looking for e.t.c / shed any light on the situation

Cheers in advance for any help

[MrMPuk]

The engine should be 2 litre, well actually 1998cc. This is available in various outputs, so the best thing to do would be find out which version you have. You can do this by posting the reg and we can tell you.

[transitman1]

Yeah the registration doc classes it as a 1998cc, but i've always called it a 2ltr, the reg is AY02 MXF

Cheers

[MrMPuk]

Well it left the factory as a 75ps.

Transit 2000, 2.0L Duratorq DI (75PS), Diamond White 73

VIN Number: WF0VXXBDFV2Y22023
Registration Number: AY02MXF
Registration Date: 13.03.2002
Registration Country: GB
Primary Features
Build Date: 12.02.2002
Vehicle Line: Transit 2000
Cab Style: Regular Cargo Van LCF
Series: 260S Series
Engine: 2.0L Duratorq DI (75PS)
Transmission: 5-Speed Manual Transaxle - VXT75
Drive: RHD FWD
Axle Ratio: 4.23
Emission: Light Duty Truck Stage III
Territory: (+)"GB"
Paint: Diamond White 73
Interior Fabric: Stylize (-I-C)

[transitman1]

So where do I go from here ? I was thinking if a new engine is going to go in, would I be able to put a more powerful engine in without having to alter everything else, we use the van to tow a mini excavator / trailer fairly often and it always seems a little gutless when under load. Is there anyone on this forum that could recommend who to buy engines off e.t.c

Cheers for the help so far.

[ginsambo]

Is fuel spraying out at high pressure from the injectors, or just...getting to the injectors?

[transitman1]

At the moment it looks like the fuel is only getting to the injectors, as when you slightly loosen off the silver 2 branch things (they sit on top of the injectors) plenty of fuel comes out. I'm not to sure on how to take the actual injectors out ? so can't say for certain that the fuel is actually being sprayed into the engine its self. Would it be worth taking the injectors out and checking them out ? (I have been told that these injectors do not need re-programming if that makes any sense) if so how would i do it ? is there a guide on here at all.

Cheers

[ginsambo]

Sorry that's what I meant - ie. how much fuel pressure is getting to the injectors, be careful if you take them out as the high pressure will inject fuel into your bloodstream. Just had an idea it might be like a 2.5Di with seals wasted in the injection pump, causing an air lock, rather than an engine problem. Maybe perservere with bleeding the injectors some more as you've replaced fuel filter. Would the ECU need reprogramming from protective limp mode to start?

[transitman1]

There seems to be good pressure getting to the injectors, although we haven't taken the injectors out themselves we have slightly undone the silver branch looking things on top of them and fuel sprays out at a fair pressure, so i'm quite confident that the fuel system works ok. However after asking my father about the last time he drove the van he has told me, that when he drove it the performance was about 50 / 60 % of its usual self and then a load of black smoke came out of the exhaust for about 5 mins after this, the van carried on for about 15 miles and then died and would not start at all. This is when we then cleaned out the fuel tank, fuel pipes, replaced filters e.t.c it tried to start but wouldn't and still won't. He also mentioned that he heard a strange noise come from the engine area although could not say with a 100% confidence that it was from the engine. I really need to get the van sorted out so any advice on this matter would be greatly appreciated.

Cheers for the help so far

[ginsambo]

I still know nothing about these engines and waiting on someone who does...but at a guess I'd say with the black smoke and possible engine knocking it could well be the injectors are f@@ked and need replacing if the fuel pump is okay. I can't see you having done any major engine damage just with dodgy biofuel, even on a 2.0 diesel. Can the injectors be serviced?

[transitman1]

I recently spoke to our local commercial ford garage and gave the van details e.t.c they said that the injectors do not need to be re-programmed which is a good thing I suppose, although if its the injector pump that would need re-programming, however the injector pump is quite new as it was replaced back in Feb of this year. Would you know how to remove the injectors so that they can be checked ?

Once again cheers

[angeleye]

injectors come out basicly like a spark plug,after removing pipes and cover seals,
suggest you have a leak off test done on injectors,or take them out and have them cleaned and tested at a proper agent,also a compression test will not hurt as will give you a basic idea if engine is knackered or valves are playing up
leak off test will be your best /cheapest option first.
when dealing with fuel system be as clean as you can clean pipes/ cover befor removing injectors, cap pipes etc or tie plastic bags over them,these systems do not like any kind of crap
only tdci injectors need programming

[transitman1]

Cheers I will try and get the injectors out tomorrow, I will also take the fuel tank out again and all pipes and clean throughly e.t.c From what i've found about taking the injectors out people seem to say that the cover seals can be tricky to remove, is this true ? or are they quite straight forward. Also should I mark the injectors so I know which port they came out of, so that they go back in the same order ? From what you've said I take it that it would be best to remove the injectors and have them tested via a garage / some one that knows what they are doing and then put them back in and see if the van works (hopefully it will). Once this is done I should then get a compression test done on the engine to make sure that is ok. what is meant by a leak off test ? my knowledge on engines them- self's is not that great (I've never had to do anything on an engine itself before).

Once again cheers for the help