MK7 Engine rough, smoke and oil in engine bay

[rossco_pb]

Going to try and find an engine - hens teeth in NZ but looks like the UK has a few on offer - any recommendations on where I might source one ?

[rossco_pb]

Slowly burrowing in and around this engine and wondering if possible to get rocker cover off while engine is still installed? Mine has the centrifugal oil filter on top and seems to foul on that and possibly some other bits of plastic sticking down from the cover. Any tricks?

[knobby1]

Slowly burrowing in and around this engine and wondering if possible to get rocker cover off while engine is still installed? Mine has the centrifugal oil filter on top and seems to foul on that and possibly some other bits of plastic sticking down from the cover. Any tricks?

Rocker cover should come off relatively easily...just remove the top filter before attempting to remove the rocker cover itself.

I had mine off some years ago and don't remember it being too difficullt.

Lord Knobrot

[rossco_pb]

Ok finally got engine out and top end off today and yep - have a hole and crack in number four. Not sure why, have had injectors tested and reports on them all indicate perfectly ok so wtf.... Bore and head looks fine - no apparent damage. I was going to get piston welded if just a hole but because of crack will now replace it I guess and then cross fingers lol

20251110_153634.jpg

[knobby1]

Ok finally got engine out and top end off today and yep - have a hole and crack in number four. Not sure why, have had injectors tested and reports on them all indicate perfectly ok so wtf.... Bore and head looks fine - no apparent damage. I was going to get piston welded if just a hole but because of crack will now replace it I guess and then cross fingers lol

20251110_153634.jpg

Holes like that are "usually" caused by injector issues.

Gearbox, timing cover, rear main seal retainer and mid-sump needs to come out to get at the big ends unfortunately. Easier to pull the engine.

Lord Knobrot

[loot]

You can remove the front bonnet,lights,slam panel,bumper and rads easily in an hour. If you can get a hoist to lift the engine out then you could look at getting a bench to work on ideally so you can play about with the engine comfortably.

Most people tend to spend the time just swapping the engine with a low milage 1. I've only read injectors causing blown pistons from over fueling. If you are confident in stripping it down and fitting new pistons etc and inspecting the rest of the engine for things like main seals,clutch,timing chain kit and giving it a bit of an overhaul where needed then happy days. There are lots of bits to these engines though.

[metalworker0]

Ok finally got engine out and top end off today and yep - have a hole and crack in number four. Not sure why, have had injectors tested and reports on them all indicate perfectly ok so wtf.... Bore and head looks fine - no apparent damage. I was going to get piston welded if just a hole but because of crack will now replace it I guess and then cross fingers lol

20251110_153634.jpg

that's a crazy picture ... you clearly see overheating /// not just in one part but in 7 points

would be interesting to see an engine designers or injector experts opinion on this .

NOTE: MAKE SURE YOU CHECK OUT THE OIL JET THAT SQUIRTS COOLING OIL UNDER THE PISTON


see here

a group of 6 pistons .. and onwards description underneath .. the damage is described as lack of lubrication or low oil pressure to piston oil jet
https://highwayandheavyparts.com/blog/p ... KoVv1CKGaM

all the best.mark

[metalworker0]

Take note of paul2012 post down the bottom of the page, link below ,
Part number for 2.4 is , 1316019 . ( note: his is a 2.2)
There is an oil gallery filter .. located as in pictures in the thread --- crank has to come out to replace this filter,if you suspect oil problems to the oil jets.

"https://fordtransit.org/forum/viewtopic.php?f=5&t=172985&p=1594722&hilit=gallery+filter#p1594722


all the best.mark

[metalworker0]

LINK AGAIN

viewtopic.php?f=5&t=172985&p=1594722&hilit=gallery+filter#p1594722

[rossco_pb]

Cheers for the info on the oil jets, will try and find them once bottom off and what, a filter under the crank???

[metalworker0]

video here 40 secs in .. also see him flushing the gallery with syringe and cleaning fluid

https://www.youtube.com/watch?v=0-zJhRk_DSI

yeah, see now why i say take engine out

there are no short cuts ... if oil gallery blockage was the cause of the piston damage. it has to be cleaned out

you'll see him also attending to the oil jets

maybe this oil filter thing is planned obsolescence, last for the first 120,000 miles on fords 20,000 mile oil changes .. then blocks up and self destructs engine once the warranty has expired or falls apart at 10 years from ageing of plastic .

all the best.mark

[rossco_pb]

Ok a nice sunny day and a n ew challenge - the dual mass flywheel bolts do not line up with the holes in the moving bit and given it a couple of smacks bu seems solid - do I have to destroy it to get it off?

[rossco_pb]

Don't panic ok found that if locked the flywheel using that very special tool (an old bike spanner) and using my home made special crank pulley bolt removal tool I could turn crank anticlockwise (from rear) and compress the innards and one by one get the bolts out - hoo-bloody-ray...

ok now the ladder stiffer thingy - yea gods what a mission lol

20251111_110959.jpg

[rossco_pb]

I just want to thank everyone on this group for the help you have offered during this rather stressful exercise for this 70 yo bloke way way down under in NZ. Have ordered a new piston, rings etc and full gasket set and while it apart going to replace turbo (it whistles) and the DMF/clutch as guess it the DMF a bit poked and the clutch comes in the kit. Did consider a non DMF but apparently can be an issue with 6 speed manual box. Now just got to wait for all the bits and clean it up and hopefully get it back together ok and then of course hope it works lol