XM poor running engine

[red_dwarfers]

I've got a bit of trouble with my XM 2.1 Turbo Diesel with EPIC injection pump. Last weekend driving on the A303 up to the CCC National rally I suddenly lost power, lots of torque and the engine shakes about so much so that you feel the movement sitting inside the car.

I've put together a video showing firstly the engine shaking at idle (though interestingly it wasn't shaking as much as it did later on) then the exhaust at idle. After that I stuck the Lexia on and filmed the parameters and a few of the actuator tests.

It may be a red herring but the stop and coolant light came on when I went to start it up today (haven't touched the car since last Monday!) and I needed to top it up by half a litre.
Also, the intermittent 'Needle lift lost' reappears every time the engine is restarted, again could well be a separate issue.



I am completely lost and have little idea where to start. A feel around the air pipes shows no obvious splits. I have a spare set of injectors and an EPIC pump...or 3 so my next thought is to swap out the injectors but don't want until I've had some more opinions. Some people at the National kindly gave me some advice but damned if I can remember much!

What do we reckon?

[Mandrake]

If it happened suddenly, is there any chance the timing belt jumped a tooth and put the injection timing out ? Just a guess mind you...hopefully someone that knows what they're talking about will have some ideas soon...

[kenhall1202]

Hi Kev,
I would check out the needle lift sensor (injector nearest cambelt end of engine) for two possible problems.
Measure the lift sensor coil resistance from the connector to see if it has gone open circuit - should read 100-120 ohms. O/C = new injector unfortunately.
Check the two pin connector and wiring adjacent to the needle lift injector for corrosion or wire damage.

Ken

[red_dwarfers]

I shall check the needle lift sensor tomorrow. I think I have a spare needle lift injector, I'll check.

[red_dwarfers]

Yesterday I finally got around to spending a bit of time on the XM. I checked the continuity of the needle lift sensor (injector nearest the belts)...open circuit! Checked the continuity of my spare and the resistance was around 100-200 ohms (can't remember exactly). Swapped the injector over using a modified spanner (need to get a suitable box spanner for the tool box really), cleared the fault on the Lexia and the fault code no longer reappears...the only trouble is the engine is still exhibiting the same symptoms.

I'm now tempted to remove the glow plug from each cylinder in turn (easier to remove than the injectors and probably a bit safer!) to try and work out if there is a specific cylinder not firing.

That's a good point on the timing belt front, I'll check that too.

[red_dwarfers]

Right. This week me and Dad have been mostly on the pull (pulling the engine out).

Fantastic news! The head gasket hasn't failed!

Engine looks a bit sad though.







Now here's the curve ball:



No 4 cylinder could have been like that for ages without anyone being any the wiser.

Paul reckons he should be able to sort me out with a replacement head and piston which is excellent

Also while we're at it.

Today I've bought:
Crankshaft seals for either side
Diff seals for either side
Valeo clutch kit
Cambelt
Engine oil
Gearbox oil
LHM
Antifreeze

To get:
CV boots
Head gasket

Struggling to get at the moment:
Plastic fork release bushes/bearings (Citroen on back order, bloke in parts is very honest and said he is reluctant to order them as it may end up being months) (GSF/AEP can't get hold of them)

To add insult to injury, when I took the drive shafts out I noticed the strut return hose has broken off, I haven't investigated properly yet so it may well have just popped off.

[addo]

OMG

That has seen better days! I hope the repairs go smoothly.

[citronut]

WOW Kev thats a case of serious melt down
little wonder it ran at all,

and looks to me that H/G had failed or on the verge of failing on No.4 which is usually called No. 1 these days

the coopers ring impression on the block and head has discolouration,
is there a chunk missing from any of the valves in that cylinder, or is it a case of the piston rings worked there way up into the combustion chamber and wreaked havoc,

looks like 1 and 3 were running very rich also Kev, very sooty

[citronut]

ps.

dont let your mum see that towel , you will have to sneak it into the washing machine but not on a whites wash

give M C Lockwood a call for the bits you are having trouble sourcing

[Xantidote]

dont let your mum see that towel

Took me a long time to find the towel White did you say?

So has part of the lip of the piston disappeared? Can't tell from photos, but has one of the compression rings perhaps broken? Was the engine consuming any more oil than usual I wonder.

Hope the rebuild is straight-forward. Depending on what the strip down reveals, might you be checking the other pistons?

[addo]

I think Chuck Norris spat in the motor. It would explain the damage.

[citronut]

dont let your mum see that towel

Took me a long time to find the towel White did you say?

no no i didnt say the towel was white as its black ( or at least it is now ) but dont put it in the washing machine with the whites

[citronut]

i have also just spotted what looks like a big chunk out of the head between the valves

[KP]

Are you stripping the lot right back down and re-assembling as it could be worth while as it would mean you can paint up the block and other bits in some HT paint and possibly put some cheap heat webbing on the downpipe and exhaust manifold while your there and keep the engine bay in great nick as i always love spending the time cleaning bits up as it means next time you need to work on it its nowhere near as dirty and if anything leaks its much easier to spot. And as Vince would say, a clean XM bay is a nice sight