MK7 Engine rough, smoke and oil in engine bay

[rossco_pb]

Ok a day of drama with our 2009 MK7 2.4L 140 RWD transit (motorhome). Going up a hill and felt vibration, thought it was road or tyre gone duff but then became aware of smoke and engine not sounding right. Pulled over and give a rev and buckets of blue smoke out exhaust and thinking turbo gone. Turned it off then it went full noise runaway for a few seconds then stopped. Open bonnet and engine oil everywhere. Popped intercooler pipe to intake and engine oil runs out. So yeah probably turbo but why the oil all over the engine bay or is there some other possible cause? I can turn engine by hand so not seized (am worried about damage from the runaway).

[T350camper]

I'd say you've got it right. Sounds like a turbo failure. When they run away it get serious...if it stopped by itself (without a mega explosion) then there's a good chance the engine is okay. Do NOT try to restart until you've repaired/replaced the turbo and removed and cleaned the intercooler and pipes. Good luck!

[rossco_pb]

Ok have taken off intercooler pipes and started it and it running rough and white smoke out exhaust on small rev and I think I saw some discussion about injector seal washers which from what I have read might explain all the oil in engine bay. Thoughts and the process to fix - hard, easy a pain?....

[metalworker0]

sort the turbo out first .

then get a it running
if its the washers .. there will be chuffing out of the oil filler hole, when you remove the oil filler cap.

all the best.mark

[rossco_pb]

Ok its chuffing like a train and not firing on number 4 - low or now compression, bugger. Now got to figure out why

[metalworker0]

Think you have a holed piston, now after reading first post again

Get a compression tester on it... if you have the injector out you may be able to see the piston with a boroscope

all the best.mark

[rossco_pb]

Yep injector out - will have a looksee but does not sound good. Are these things known for blowing holes in pistons?

[metalworker0]

Yes, possible for injector to fail, spray fuel to one side and concentrate heat on one part of the piston and melt and crack it. been reported here a few times.

all the best.mark

[rossco_pb]

Ok best I can tell there is a "soft spot" on the piston right front- Got a pic but so much oil and my camera not the best but yep would say piston got a hole in it and interesting about the injector... If I get it fixed not sure what the cause is - I guess injectors can be tested and if they are ok then maybe suspect the remap the engine had a couple of years back or the EGR deletion...

[rossco_pb]

Does anyone know if the pistons can be pulled out from the bottom to save pulling the head and check bore etc from below?

[metalworker0]

Engine has to come out to pull pistons ... as there is a ladder frame (stiffener) underneath it, that has to come off .. to get this ladder off .. the gearbox has to be removed. as the gearbox bolts go into it ,

this thing .. ford call a stiffener .. is between the engine block and the sump

https://i.ebayimg.com/images/g/riMAAeSw ... l1600.webp

and shown in place here

https://tpuk.net/media/catalog/product/ ... 10fd_1.jpg

As you can see , has to be removed to get at the rod bolts .

it may be possible to remove box .. do a lot of supporting and ancillary removal .. but in the end, faster to remove the whole engine.

Pistons never ever come out from the bottom on this type of engine design .. always from the top with head removed.

video RWD piston hole --- somehow late 2016 2.2 .. engine dismantle showing piston at 20 mins in

https://www.youtube.com/watch?v=NPLxl0lPX9M

all the best.mark

[metalworker0]

this gives you a better idea

as i could only find one part on one diagram .. another on an another diagram, this chap has put them all on the same page .. he calls it the underframe, its an LDV convoy .. believe same engine

https://vandogtraveller.com/ford-duratorq-ldv-convoy/


all the best.mark

[rossco_pb]

Cheers for all the excellent info - guess the engine coming out (somehow lol)

[rossco_pb]

Hey Mark, that video really interesting as hole in number 4 looks to be in the same place (that I can feel) on my engine - coincidence or?

So there is an alloy frame on the bottom of the block that is also connected to the gearbox and can't be removed without gearbox coming off or is it just the bolts from gearbox into that piece? Could not quite figure out the connection...

[metalworker0]

well the amount of stuff you are talking off the engine ... head , manifolds sump, camchains... in the end, even if you could do it with it being still connected to the gearbox ..... you'll end up with just the block supported by the engine mounts.. and maybe struggle to get it to that stage

others here will tell you if they attempted it your way and found it any easier

one downside is all the dust and crap blowing about, you need it in a clean environment, you being upside down on your back cleaning the mating surfaces... i don't know what other troubles .. i've only seen the block left in place on simple engines like, ford pushrod stuff from the 70's.

Plus.... is the i don't know .. leaving it in place will cause other issues


Note : sump has to drop down low enough to clear the oil pump and pick up tube.
Will the steering rack have to come off, anti toll bar , drop links , , will the bottom cross member have to come off ... if they don't have to ... you are working through gaps

Cross member attached by bolts that are in captive nuts in the chassis rails that sometimes break loose and turn ... or are a nightmare undo.

all the best.mark