New engine issues *Desperation station*

[mickykendal]

Hi all,

I come to you in a state of pure desperation!

I have a 2019 2.0l RWD ecoblue tipper. I was having issues with my engine (150k miles), lots of white smoke, smelled like it was trying to kill anyone within 10m of it and was absolutley drinking diesel (16mpg). It felt like it was missing when cold. Injector seals were leaking and the injectors were stuck, totally flat power delivery. I made the decision, rather than throw money at that engine, I'd buy a reconned block/head/sump and start fresh, as I've heard about valve seats and warped heads.

I swapped all the ancillaries over and fitted it to the van.

It hunts for idle and wont rev much more than 2k, it's not a hard limit as if it's limp, but when it gets there, the battery light and glow plug light flashes then it rebounds down and will stall if not caught with a bit of throttle. it wont run for more than 30-50 seconds without stalling and once started a couple of times, it doesn't seem to start again for a short while. Fills my lock up with fumes, but not like before the change, more like an engine not running right.

Forscan is showing a crankcase sensor fault (P0335:02-64) and sometimes internal control module engine rpm performance (P061C:01-26). My topdon scanner shows more faults such as ABS and SAS. All can be cleared, but show straight away once turned. RPM seems to be displayed correctly on the clocks and in forscan.

I had the DPF, EGR and AdBlue deleted in the PCM by a very reputable mapper, and the contents of the DPF 'fell out' when I took it off

Here's a list of things I've tried so far:
Second hand injectors with test sheets, coded with forscan. Switched back to old injectors, coded, neither helped
Second hand HPFP
New Camshaft sensor
New crankshaft sensor
Calibrated crankshaft sensor in forscan
checked continuity on crankshaft connector harness
stripped engine loom from crankshaft harness to PCM - no cable damage
Checked, double checked, and triple checked engine and fuel pump timing, it's 100% correct
Took PCM back to mapper, who looked at it, made some changes, not sure what, but said if it didn't work, he wanted it back to put it back to his first iteration.

Somethings that may be irrelevant, but will mention just in case:
I put a brand new clutch and fly wheel on
I put a brand new turbo on
New vacuum pump fitted

One bit of info that may be relevant:
Half way through the transplant, the old block fell over, landed on the vacuum pump (hence new one) and damaged the oil filler cap then lay on the exhaust side. There wasn't much still attached at the time, HPFP was, which is why I tried another one.

I have a second hand fuel rail to fit, and have been advised to check the reluctor ring, despite this being a reconned block.

As you can see, the parts shotgun approach isn't working.

Does anyone have ANY suggestions for what could be causing this? Even voodoo magic would be considered at this point

[metalworker0]

Nobody knows the codes by heart and well near all rely on google to show what codes mean.

From that and your two codes: point to crankshaft sensor , wiring or not getting signal because of the wiring or pins in the PCM or the incorrect voltage, not enough voltage for pcm etc. damaged flywheel is another cause.

An engine change would have had grounds undone,

The vehicles BEMM (body and equipment mounting manual) says where these are

You don't say if custom or mk8, so i cant lead you to it

Put into google ford transit 2019 BEMM, insert custom or mk8 - it's freely available

Then check out where the grounds are.

BTW .. was watching a few videos on youtube over the last couple of years and they are saying a huge percentage of parts especially after market electronics, sensors etc , are faulty out of the box.

all the best.mark

[mickykendal]

Thanks Mark,
It's a mk8 chassis cab.

I've found the bemm so will have a look through that. I have checked what earths I can find and they're all good.

I could quite well believe the stats on parts arriving DOA, but i changed them as an exercise of elimination. the sensors were fine on old engine, should be fine on new, I'd be desperately unlucky to have my sensor die between swaps and a new sensor doa!

[metalworker0]

what else is there on the ecoblue to check

Throttle body in the inlet manifold - if this has bust gears in it .. it will not open and strangle engine - believe its there to help the EGR pull more exhaust into the cylinder by creating vacuum and help engine shut down more smoothly .. but at fault and stuck shut it will cause all sorts of problems not documented here yet.

special backlash gear in valve train .. this can be assembled wrongly - not sure what happens

Think you should do a compression test

Bad fuel

metal swarf in fuel caused by failing high pressure pump

all the best.mark