Interesting one this that I think may be of interest to some, the enthusiastic owner of this nice twin turbo zed bought it from a dealer before Christmas, however from day one it was not quite right somehow and over the past few months the running issues had got worse.

 

However a more pressing water leak issue and heater matrix failure developed recently and hence why we got involved. The main water leak was quickly established as a pin holed steel water matrix pipe, and a very, very leaky matrix. The matrix and pipe where subsequently changed, the extremely rusty brown water we flushed from the system was more than likely a contributor to the two leaks.

 

So that just left the running issues, with more attention now paid to this it soon become clear that the engine was very unhappy, running very rough at idle with hesitation when applying power and the ConZult was showing excessive afm voltage, no errors but when left idling would get slower and slower until it would cut out. Now the strange thing, when restarted the engine would burst in to life and run clean and smooth, but for around 15 seconds only and then the repeat of the rough running and eventual cut out.

 

Among other small tune up adjustments a boost leak check revealed a huge leak under the plenum, a quick disconnect of the afm and restart should have been enough to resolve the boost leak for the test as the afm signal is now just on a get you home default map, however it was very much the same.

 

With the many possibilities that could cause kind of issue choosing the best way to go forward and to not get bogged down in time consuming fault finding, so a simple back to basics approach is used and soon a visual look over the engine revealed the problem, Jamie's keen eye spotted that the injector colour was bright red.

 

To those that do not know this means they are smaller flowing non turbo injectors in a twin turbo engine.

So to prove the point an N/A ecu was slotted in and as expected the engine started and ran perfectly, revving freely and idling smoothly.

 

So who, why and when and again WHY? no way to find out but now the fix is to strip out and replace the injectors with the correct flowing ones. As an addition to the oddness of the wrongly fitted injectors the cambelt was revealed through a broken cam cover to be in questionable condition, the dealer had suggested during the purchase on more than one occasion it had been replaced, well it defiantly needed doing now?

 

 

So we know how this starts, start a methodical strip of all parts to see what's going on.

 

Follow the pics as the strip out started today, the plenum removal starts first.

 

The plenum was soon off and the gasket was revealed, the condition as can be seen is very second hand

 

 

Closure inspection reveals a large section of the gasket missing, that's the dangers of reusing old gaskets.

 

 

 

 

As mentioned the cambelt was revealed by a break in the cambelt cover, in fact that area of the cover had been catching the belt.

 

 

So the belt was stripped out so that can be changed, the red injectors are very visible now in the back ground

 

A broken cambelt tensioner body was discovered, the break bizarrely looked clean??

 

 

Continue next thread.

So back to the injectors and so the complete rail was removed with the 6 injectors in one piece, the injector port seals looked to of been reused one's and clearly not very well, all six showed signs of damage, how they were sealing is a mystery.

 

 

 

 

 

All stripped

 

 

 

So there we have it for today, covered up to keep any stray bits out, back in the morning to carry on. will follow up with the conclusion tomorrow.

 

Jeff

Edited March 29, 201015 yr by JeffTT

that's a great write-up Jeff and well done the both of you for finding the faults :bow:

Very interesting- Thanks

Is this the same car that had the bodged wheels?

not a non turbo block is it? replaced and the turbo accessories bolted on? lets see the pistons lol

Is this the same car that had the bodged wheels?

 

No.

 

Jeff TT

Thats something, I could only imagine what other evil would have lurked if it was.

Mmm... yes all very odd, sadly seem to be coming across more mysterious faults and odd workmanship than in previous years.

 

Jeff TT

Can we know where this car came from? Looks pretty bad i must admit, lots of work to do on it!

Can we know where this car came from? Looks pretty bad i must admit, lots of work to do on it!

 

Well at this time I do not know, the owner is keen to have it running as it should and as in many cases prefer to get it done somewhere other than the supplying dealership, will ask him when he collects.

 

Jeff

Obviously a poor quality of car thats been sold, not always the dealerships fault i suppose but I did just wonder if it was from your "usual suspects" list LOL You have PM btw... or you will in a couple of minutes!

great info well done again.:thumbup1:

 

dan.:biggrin:

Ok so following on from yesterday, had a few hours allocated to carry on with the engine work, so a thermostat, inlet hoses, rebuilt tensioner, pulleys and a cambelt ( water pump already replaced ) soon fitted and back together

 

 

 

So back to the injector problems, stripped out yesterday and the ports all cleaned and new seals fitted and greased ready for the injectors.

 

 

So a tested replacement rail and injectors fitted with new fuel link pipe, and the white stuff everywhere is talc, used previously by the owner to trace a fuel leak.

 

 

So matting faced all cleaned and gasket at the ready, plenum back on in the morning, connect up the loom and fuel pipes and should be mainly complete by lunchtime, back with final completion pics then.

 

 

 

Jeff TT

BLOODY HELL thats a lot of talc to fill up the lower plenum (JOKE!!) :tt2:

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

I know its tissue!

Is it me, or is there a lot of people out there that seem to do a bodge job on these cars recently?

BLOODY HELL thats a lot of talc to fill up the lower plenum (JOKE!!) :tt2:

 

I know its tissue!

 

:biggrin: :clap: :biggrin:

 

 

Jeff

Edited March 30, 201015 yr by JeffTT

I have seen similar a couple of time down here in kent.

I seems theres alot of breakers and back street garages repairing Z's to sell on . as we know theres a lot of spare engines out there so people seem to be mix and matching many odd parts .

alot of horror storys my end as well at the moment . Maybe its the time of year for it :).

 

Daz.

( D2 )

Out of curiosity....Dazkent are you from "D2 vehicle services" in strood?

Out of curiosity....Dazkent are you from "D2 vehicle services" in strood?

 

What "Daz" with D2 under his name whos posting from Kent where Strood is.Id say no probaly :pinch:

:rofl:

what "daz" with d2 under his name whos posting from kent where strood is.id say no probaly :pinch:

 

:yes:

Edited April 2, 201015 yr by JeffTT

well just i didnt know strood was in kent ok, and dont really know what Daz is short for. but i did find out it was him as i checked out his recent posts, but couldnt be bothered to edit my post