Is it mechanical or air in the fuel delivery?

[roofraisers]

A quick way to test if any valves have any damage & without removing the cylinder head.
Turn the engine over so the required cylinder is on Top Dead Centre compression stroke.
Introduce compressed air into the cylinder via the glow plug hole.(make an adapter to get a really air tight seal or use a rubber cone end on a blow gun)
If you hear (or feel) air hissing out of the inlet or exhaust manifold, you've got a damaged valve.If not... I reckon the cylinder should be air tight at the top end.
If the piston rings are worn or broken you should hear air in the oil ways as it escapes the crankcase.


Nigel

[progroup]

A quick way to test if any valves have any damage & without removing the cylinder head.
Turn the engine over so the required cylinder is on Top Dead Centre compression stroke.
Introduce compressed air into the cylinder via the glow plug hole.(make an adapter to get a really air tight seal or use a rubber cone end on a blow gun)
If you hear (or feel) air hissing out of the inlet or exhaust manifold, you've got a damaged valve.If not... I reckon the cylinder should be air tight at the top end.
If the piston rings are worn or broken you should hear air in the oil ways as it escapes the crankcase.


Nigel

Ditto everything you point out Nigel; these tests I am familiar with on almost any engine. I will perform these tests before removing the head for sure. The London based supplier 'Peer Parts' assures me that they will ship another complete kit [head, belt, bolts] by tomorrow 2PM if I resolve that the head is defective. They are already convinced; we are just going through the motions.

Today, after I return from some very desparate client calls; I will be doing a short video of the vehicle running and a visual of it prior to oil spray up from the cam, and running w/valve cover back on. I will video the TWO tests you claim above as well.

I have already sent pics to the supplier and have had a few phone calls this morning to figure out what options we have.

I have had these types of problems many times when I twisted wrenches for a living; but that is why I bought new cars since 1986 [my first new one was a Hyundai Excell 1500cc]. My fetish for diesels is to blame for my predicament. Also, our Government for not permitting new diesel engine cars/trucks into Canada.

I'll be posting more pics at my 'dropbox' website and the video on Youtube at bit later! Look for it, it should be quite revealing!

Cheers,
Dave

[roofraisers]

In addition to the above post,
If you take off the coolant reservoir lid whilst the compressed air is applied & the coolant comes out of the reservoir or you hear a lot of air bubbles...... you've guessed it..... chances are your head gasket has gone on that cylinder.
This test could be done if people are uncertain whether they have or haven't done in their head gasket, without the risk of doing any damage, if no heat damage has occurred.

Nigel.

[progroup]

see my YouTube 7 minute video on the subject...

http://www.youtube.com/watch?v=yCwUV2sTQGI

More coming, stay tuned because I must now remove the head to further inspect

[199andy]

Hi Dave
I have seen this a few times on these engines.On any new head fitted it is important to remove the cam shaft and rockers so that the pegs/buckets that the far end of rockers locate into are fully tightened.If they are loose it increases the valve clearance and eventually the rockers jump out causing all sorts of damage.When the rockers and cam are refitted then adjust the valve clearances.
Andy

[progroup]

Hi Dave
I have seen this a few times on these engines.On any new head fitted it is important to remove the cam shaft and rockers so that the pegs/buckets that the far end of rockers locate into are fully tightened.If they are loose it increases the valve clearance and eventually the rockers jump out causing all sorts of damage.When the rockers and cam are refitted then adjust the valve clearances.
Andy

You are totally correct Andy, and it ticks me off supreme to have to do this. My very first question to the supplier was "do I need to do any adjustments" to which the reply was "no"!

Stupid of me not to! This 2nd time I have checked clearences and tightness all okay!

However, my confidence level is shaken since I haven't driven more than a week yet!