I don't usually ask for help

[meerkatmag]

https://youtube.com/shorts/x0HCCcKgkfU

Got to be one of the world's best engines. That's amazing.

[Chug]

I've got both engines out and the holed engine stripped of ancillaries and the donor engine almost stripped, just the clutch and thermostat housing to remove in the morning, then a good clean and I can start fitting all the bits on the donor engine. I'm working in a field and with all the extra hassle that brings when trying to jack up or lying under at 62 yrs old I'm feeling it.

Donor engine in left van(done around 100,000 miles) and holed engine in the right van, the holed engine was from the middle van originally

https://youtube.com/shorts/l_V3VZsPP94

[cherniy_chack]

I can't open the video on YouTube in Ukraine. It says the video has restricted access.
I think that the connecting rod broke, the connecting rod first pierced the cylinder liner, which caused water to get into the oil, and then the connecting rod pierced a hole in the engine crankcase, which caused oil to leak out of the engine.

[Chug]

Had a few little problems slow me down today but the engine is sitting in the engine bay ready to swing in and bolt up in the morning, but I ran out of light and I'm not gonna feck about with a heavy swinging engine in the dark, looking forward to a few beers tonight coz I'm knackered.

https://m.youtube.com/shorts/kz2lPMfpLQ4

[Chug]

I didn't get much more done today, but the engine is bolted to the gearbox and sat on it's mounts, I had a problem with the intermediate plate between engine and gearbox after getting the first bolt in I realised it was crooked and had to start again, then the second time I couldn't get the engine lined up for ages but after a bit of a struggle I got there, oh how another pair of oily hands would be helpful at times!

[dumper]

Yes chug they can be a pain sometimes fitting the engine onto the gearbox with it in the van at work used to remove the engine and gearbox as a lump and replace as one but you need a hand Crain and hard standing

[Chug]

Yeah I usually take engine and box out together and I was in the middle of doing the hard standing for a 24' x 12' concrete sectional garage before this happened too dumper!
As it is I have an A frame and block tackle standing on scaffold boards and have to swing and drop the engine on a board across from front crossmember to g/box and then move all the lifting gear a foot then lift and drop the engine on floor, it took three lifts and moves to get it back in engine bay.

[Altransit]

Mucho respect buddy

It's 25 years since I messed around changing a diesel engine and box in a van, and that was at least on a hardstanding on my front drive. I definitely couldn't do it now (or 10 years ago!)

[Chug]

Cheers Alex, I was in the middle of building a garage to hopefully get my turbo engine finished and fitted in the truck later this year, I didn't for one minute think I'd be swapping engines halfway through the build!
Anyway the saga continues, she starts on the button and ticks over lovely and smooth and revs up to quarter throttle fine, but ask for any more than that and she coughs and splutters, I'm sure its gotta be a fueling issue as she revved up fine on very first start with fuel direct to IP, so I'm almost there but not quite, I'll have to spend another day on it tomorrow, its frustrating!

[Chug]

Its got fuel direct from tank via electric pump to injection pump, (no lift pump, no fuel filter) I swapped the injectors, still no different, removed stop solenoid and took out the plunger, still no different, played with pump adjustments, still no different.

Its blowing out smoke that smells like unburnt fuel, almost like its putting too much fuel in, but interestingly if I pour some diesel direct into the intake manifold, the revs start to climb and I can catch it on the throttle and she seems to clear and rev and I can hold it at 3/4 throttle no problem and rev up to full throttle, but as soon as you let the throttle back past halfway she starts spluttering and smoking again.

The only real thing different to the first start when she revved up fine is the intake manifold and exhaust weren't fitted then, the exhaust makes no difference, so I'm gonna try taking the inlet manifold off next.

Anyway here is a video of it starting on the button and revving first part throttle ok, then spluttering and smoking, then I add some fuel to the manifold and catch the revs and she holds the revs fine and the smoke clears.
https://youtube.com/shorts/qUdGt6XbHzc

[meerkatmag]

Could it be your ip is knackered? Fuel pressure low so it's not atomising properly in the cylinders.

[Chug]

I don't think it's the IP because it worked perfectly before the engine got holed and there is plenty of fuel coming out when I crack the injector unions and it started and revved the full rev range properly when first started up on the ground before I fitted the engine, the only difference since then is I've fitted the engine and it didn't have the inlet manifold on for the first start, so this morning I removed the intake manifold hoping to find a rag or glove or some obstruction but there's nothing to be seen, but I still tried it again and it doesn't run any better even with the manifold off again, it does seem like a lack of air to me as there is plenty of smoke from unburnt fuel, so I'm stumped.
You can clearly hear it revving cleanly in the first start video https://www.youtube.com/shorts/kz2lPMfpLQ4

[meerkatmag]

You can clearly hear it revving cleanly in the first start video https://www.youtube.com/shorts/kz2lPMfpLQ4

Does it sound like there's not much compression there when you're trying to start it. Turns very fast and easy. Have you done a compression test?

[dumper]

Maybe sticking valve or piston rings my 1989 190 had cracked piston’s it had done a lot of miles and was running ok I had got a set of new injectors for it from work when the last di left the fleet couldn’t get number 4 out during foot and mouth I decided it was coming out even if I had to take the head off and that’s when I found all four pistons cracked .
The same model year we had a recall and Ford changed the pistons on all of them.

[Chug]

Turning fast coz I was using 24v to the starter, to give it the best chance to start its slower now its back on 12v in the truck.