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Discussion Starter #1
Hi all

driving my 2008 2.0 hdi expert van on the motorway this morning at 70 mph when there was a sudden loss of power.

no bangs or smoke but just sudden power loss.

pulled onto hard shoulder and van ticks over ok but when trying to rev the engine it sounds like a bucket of spaners and on about 2 cylinders.

could only drive in first gear on hard shoulder but wouldn't pull up a slight incline.

got a mate to come and tow me home and have van in the workshop.

no warning lights on dash but a bit of white and fuel smelling smoke coming from exhaust.

does this soung like the turbo is on its way out or anyone any other ideas?

any help appreciated.
 

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Discussion Starter #3
Hi trustme

haven't used a code reader yet. no engine management lights showing on the dash.

I have a cheap basic code reader but probably not much good on diagnostics.

I will see if i can get anyone with planet to give me a reading.

thanks
 

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2 likely causes turbo failed but this does not sound like turbo failure and second is broken rockers.

From your description it sounds like broken rockers as when they break the valves stop opening but as there are 16 in total it can run if some are still intact but wont breath very well so will smoke and the cams will hit the broken parts of some rockers making a racket.

A 3rd but less likely possibility is your EGR valve has fell to bits internally but this makes them undrivable with a lot of smoke but does not usually sound rattly
 

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Discussion Starter #7
thanks for the replies R406 and salster

would a compression test with the injectors out comfirm broken rockers?

or any other method of determining wether to go for broken rockers or turbo?

is this a common problem on 2.0hdi engine?
 

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Personaly having had plenty experience of these engines i would go straight for the rockers :)

Yes its common usually after 150k miles or so

You need the injectors out to get at them as the injectors go through the cover removing the injectors is the hard bit they sometimes dont want to come out!

You could remove the plastic cover/inlet to see in but you can only see half the rockers that way

I found it best with a running engine to loosen each injectors clamps to ensure it will move before dismantling as any stubborn ones will be loosened by the heat and compression pressure.
 

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Discussion Starter #9
thanks for the reply R 406

Any particular order in taking out the injectors or any special tools required?

I was having a quick look tonight and would seem to be 24mm head but would be akward getting a open end spanner on without removing fuel pipes first.

is there a special socket that can fit over the injectors without damaging the plastic electrical connectors?

with the injectors removed is it a fairly straight forward procedure after that?

hoping to have a go sometime tomorrow.

thanks again.
 

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once you have taken the clamps off and fuel line then the injectors just pull out but you may have to wiggle them, i would also fit new injector seals when refitting
 

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the big nut only takes the electrical part off, do this as a last resort only as theres lots of small bits in there to lose. first loosen injector clamp bolts and run the engine until you get blowpast as R406 says its the easiest way to get them to move. getting the injectors out is the hardest part, i had to get a specialist guy in ballymena to remove injectors at a cost of £240 the other week because the vehicle would not start.
 

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Discussion Starter #12
Hi all

stripping engine last night and have run into a problem.

got the plastic inlet cover removed (took over an hour finding all the bolts, especially at the back of engine).

took the nuts off the injectors and they popped out very easily so I thought we were really getting somewhere.

took all the bolts I can see from the cam cover and removed the top bolt and slackened bottom 2 from the injector pump, but can't get the cover to budge. It isn't moving at all!!

Do I have to remove the injector pump completely and if so does the timing need to be locked?

Is there anything I have missed removing?

Is it a normal gasket below the cam cover or is it a liquid type?

By the look the engine has never been taken apart before so everything should be as it left the factory.

Any help greatly appreciated as really need the van on the road asap.

thanks
 

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yes set up timing remove belt and remove the injector pump. no gasket on cam cover, just gasket sealer, double check all cam cover bolts are out, from memory i think there is 28?, look for timing marks on cams which line up with the 2 black links on the chain. also injector studs also hold cam box on. when you have them all out lightly tap cam box and it should split.
 

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Discussion Starter #14
Bit of an update. bought a transit van to get me running again as hadn't time to work on the expert.

Took the belt and cams off the engine at the weekend and the rockers are all ok.

What is recommended next?

head off to check the valves or drop the sump and remove the piston?

any ideas anyone??
 

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take all the rockers out and check them carefully sometimes they dont break just bend it could possibly have dropped a valve but once rockers are out that should be obvious.

I personally would not take a head off unless it has valve problems also check the chain is on correct teeth on cams as partial seizure of the fuel pump can make the pulleys move on the cams knocking everything out even though it looks right.

IF you want to remove pistons they need to come out from the top so it would then be an engine out job :(
 

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Discussion Starter #16
thanks R406

another update

took the engine out yesterday thinking problem must be piston rings as rockers and valves looked ok on visual inspection.

removed head and poured some petrol into the chambers to see if it disappeared passed the rings, but it didn't!!

put the head back on and turned crank over by hand and seem to have compression on all cylinders!! (hoping to get a proper compression test done over next couple of days).

assuming problem is somewhere on head ie sticking/bent valves or rockers slightly bent.

few questions-

how do you test the rockers for any any that could be slightly bent (all look ok on visual inspection) was thinking of swapping over the rockers on number one cylinder with some of the others to see if that affects compression, but this means rebuilding the engine and taking apart again.

what are the compression reading I should be looking for on these engines?

what are the torque settings and sequence for tightening the head bolts down, and do you need to replace the head bolts?

any helps/comments appreciated:nod:
 

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i do not think your problem is sticking valves but easy to check when the head is off, a new set of rockers and lifters would cost about £230 in ecp. i think these and possibly a camshaft will sort you out.
 
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