Engine probs???

[cook0505]

Hi,

I have a 2000 smiley front tipper. It has been running absolutey fine until the other day it suddenly became really sluggish, very loud, rattly and struggles to start. I can't even drive up small hills unless in 1st. Does anyone have any ideas. Fuel filter, oil filter and oil have been changed recently. It did this once before (a few days ago) but rectified itself after a few minutes.

Thanks.

[MinorMatt]

Does it chuck out a lot of smoke when it happens?

[cook0505]

Only on start up, not when driving. Actually never smokes on start up when running well, and does not smoke until this problem occurs.

[MinorMatt]

What I meant is "Is it smokey when the problem happens"

Does it go away if you switch it off and start again or allow it to cool down or is it permenant

[cook0505]

Sorry, should confirm that when the van has this problem it does not smoke, nor does it when it is running well. On start up the van does not smoke unless this problem has occured.

[cook0505]

The problem has only happened 3 times, and normally when the van is turned off and allowed to cool down, then it is fine on re-start. But this time it did not seem to make any difference.

[cook0505]

OK, so just went out in the freezing cold again to start and run the van. It seems that Minor Matt is correct, it runs and starts fine when left to cool down for ages. Still does not help solve the problem though. ANy thought?

[MinorMatt]

Ok,

Im thinking about this - its a slightly odd one

It cant be overfueling otherwise you would get thick black smoke.
So it cant be getting enough fuel in one way or another

I suggest doing the leak off mod but I dont think it will make a difference based on the symptoms - but its worth a go. But that involves moving the little pipe on the injectors that takes the excess fuel back to the tank to the front injector.

If you disconnect the 2 fuel lines at the back of the filter and crank the engine do you get plenty of fuel coming through?

Do you run on straight diesel or use veggie oil (or has it had veggie in it recently?)

The other thing I would look at straight away is the timing, its quick and easy to check with a 13mm drill bit and a 6mm one

I assume its a non turbo?

[cook0505]

Thanks for the info, although most of it is beyond me. It is always diesel. One thing that may be worth noting is that it did a run to south-west france about 6 weeks ago with no problems (about 900km) until the last 500m of the journey it did the thing mentioned above. The fuel ran low at one stage and we were not sure if was something to do with it i.e. dirty fuel? Thanks again.

[MinorMatt]

Where are you? - if you are vaguely nearby I will come and try a few things

[cook0505]

Thanks for the kind offer but I am in North Bucks, the van is at my in-laws in Birmingham until the weekend ( if it will drive OK). Too far from Southampton I think.

[MinorMatt]

Not near Brum any time soon either

Are you willing to try a few simple mechanical things to help us work out whats wrong? Have you got an 18mm ring spanner, a 13mm and 6mm drill bit?

[cook0505]

More than happy thanks. I have all sorts drill bits and many spanners but will have to check sizes. Iam out all day but could do some tests in the evening. Thank you for your help, it is very kind of you.

[MinorMatt]

ok...

To check the timing:

Look at the backplate of the engine behind the fuel filter you will see a raised "boss" with a hole in the middle. It is very unlikely but there may be a white plastic cover there which will pull out

Put the 13mm drill bit in there blunt end first (13mm is crucial here) put the spanner on the crank nut at the front of the engine on the bottom pulley (there may be a cover here that needs to be levered off) and slowly rotate the engine whilst applying gentle pressure on the drill bit. At some point it will slide in further and lock the flywheel.

At this point remove the little rubber bung on the front of the black plastic cambelt cover (its top left). Have a quick look in there with a torch and you should see a zinc passivated piece of metal with a slot in it which should be perfectly in line with a hole in the injection pump body. You should be able to insert the 6mm drill bit in there. If you can the timing is fine. Remember to remove the drill bits and put any bungs / covers back.

Leak off Mod:

Firstly go to a motor factor and ask for some leak off pipe - you will need about 2ft of it if you have a choice. Its thin fuel pipe.

Next look at the injectors, the one at the back will have 2 pipes, one leading to the next injector and the other going to a T piece in the main fuel lines. You need to remove this pipe and connect your new pipe to the main fuel line. Now look at the front injector, it will have a blank on it which you need to take off and put on the one at the back where you took the pipe off. Connect your new pipe up where you just took the nipple off.

On the later vans air can collect above the front injector (its the highest point in the system) by moving the pipe it will take the air that collects there rather than allowing it to build up.

Next (and I would do this even if its running well) I would bypass the EGR valve (this stops the engine ingesting its own exhaust).

To do this you need a screwdriver, undo the jubille clip at the inlet manifold end of the air filter pipework. There is a rod that goes between the injection pump and a butterfly carefully pop this off and cable tie the butterfly totally open. Put the pipework back and do the butterfly up. I would also put a solid metal plate between the assembly and the pipe that goes to the exhaust manifold - although in theory this shouldnt be necessary.

If the timing is up the spout thats obviously the problem and chances are you need a new cambelt (about 200 - 250 at garage rates). If its right or pretty damn close it will obviously be something else and the other 2 bits are worth a go

[cook0505]

Thanks again for all your help. Have not had time in daylight to do what you suggested but will try this weekend. Did lift the bonnet and unscrew the bottom of the fuel filter though. Someone recommended me doing this as they said that there could be a lot of water in the filter. WHen I unscrewed it I just had a lot of air escaping and then diesel so I did it back up. Is this normal?