Diesel Diagnostics

Back to Forum

Post a Response

Mercedes Benz Sprinter 2.1 2003 - Melted piston, injector failure? - Fixed #

Posted by Lindsay Flaxmer on May 11, 2011, 6:28 pm

Year of Manufacture *: 2003
Engine Size and Code *: OM611.981 2.1cc

MELTED PISTON/INJECTOR FAULT?

This sprinter was smoking & running very rough, had no compression on number 4 cylinder, done around 280,000 miles, customer decided to have a remanufactured engine.
We sourced and fitted a full engine from a reputable engine builder, we sent injectors and pump to be tested by diesel service centre (they were only 2 months old) they tested ok and were refitted.
After reassembling and running up to temperature, all seemed good sweat as a nut, extended road test carried out (twice) then handed back to customer with a daily check notice for the driver.
After 200 miles (first day out) I had to recover it for loss of power & running rough.
Tested compressions, number 4 cylinder very low, removed cylinder head to find piston melted and cylinder bore scored.
So Guys
what do you think?, thought I had the injectors covered, I have checked for broken wires in the engine wiring loom they all look good.
Could the ECM cause this? Could it be an injector even though they were checked?
NO FAULT CODES STORED.
I am going to have to put this right, but my biggest fear is that it may happen again with the next engine.
Yours in hope!!!
A very desperate
Lindsay Flaxmer

Re: Merc Sprinter - Melted piston, injector failure?

Posted by Darren Cotton <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT1876' width='330' height='300' border=0 style='border:none;'> on May 11, 2011, 8:57 pm, in reply to "Merc Sprinter - Melted piston, injector failure?"
Darren Cotton

Hi Lindsay

I am not familiar with this engine or its system, But cylinder four had loss of compression on the first engine that was your original fault...and now you have the same with the new engine...

I don't see how an injector or ECM will melt a piston??........

Does this engine have an EGR?

Darren

Re: Merc Sprinter - Melted piston, injector failure?

Posted by Lindsay Flaxmer <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5521' width='330' height='300' border=0 style='border:none;'> on May 12, 2011, 8:36 am, in reply to "Re: Merc Sprinter - Melted piston, injector failure?"
Lindsay Flaxmer

Hi Darren,
Yes it is the same cylinder that’s my big worry, I have to find the cause and it’s not that obvious, it hasn’t got EGR.
The reason I question the injectors is that a couple of years ago we had a fiat doblo with a melted piston, we fitted new pistons & rebored, fitted new injectors with no further problems.

Thanks for taking a look & your input.

Lindsay

Re: Merc Sprinter - Melted piston, injector failure?

Posted by Kev Gundry <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5245' width='330' height='300' border=0 style='border:none;'> on May 12, 2011, 1:40 pm, in reply to "Merc Sprinter - Melted piston, injector failure?"
Kevin Gundry

Hi Lindsay,

I have had a few of these in my time, and my findings are that the engine has been overheated, and it's always No:4 piston that melts. I imagine that the engine repairer would have put the old pistons back in, as they are £1000 with new rods because the piston was modified so you had to fit new rods as well.
we rebuilt one about 2 years ago that had overheated we removed the head which we sent for testing came back ok, we checked the pistons and bore for wear refitted the head 2 weeks later it was back with no compression No:4 piston melted

I just insist that i fit a mercedes exchange engine they come with everything on them including a new turbo just bolt it and go if they don't want that done i just refuse to do the job, the cost is not that much different time you have swapped all the parts across.

as i say this is not uncommon, and when you think about it, if it has lost all it's coolant which cylinder is going to get the hottest

HTH

Kev Gundry

Re: Merc Sprinter - Melted piston, injector failure?

Posted by Lindsay Flaxmer <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5521' width='330' height='300' border=0 style='border:none;'> on May 12, 2011, 6:32 pm, in reply to "Re: Merc Sprinter - Melted piston, injector failure?"
Lindsay Flaxmer

Hi Kev,

I recovered this vehicle myself within 30 minutes of it breaking down, it certainly didn't seem as though it had been hot & the coolant level was spot on.

Now wishing that I had fitted merc unit, cant see me getting any help from the engine builders although it is being sent back to them tomorrow for inspection.

Many thanks

Lindsay

Re: Merc Sprinter - Melted piston, injector failure?

Posted by Kevin Gundry on May 16, 2011, 10:28 am, in reply to "Re: Merc Sprinter - Melted piston, injector failure?"
Message modified by board administrator May 16, 2011, 2:36 pm

Hi Lindsay, i suspect that it had already been overheated before it was rebuilt.

Kev Gundry

Update

Posted by Lindsay Flaxmer on May 20, 2011, 1:51 pm, in reply to "Mercedes Benz Sprinter 2.1 2003 - Melted piston, injector failure? #"
Message modified by board administrator May 23, 2011, 4:20 pm

VEGE have looked at the engine and say that they can guarantee me that this failure was due to an injector malfunction, they are going to have to charge me £650 + vat to sorting it, I have had the injector retested 3 times since engine failure and it hasn’t failed.
I have now ordered 4 brand new injectors £850, hope to get the engine back next week to reassemble and keep my fingers crossed.
Note: If anyone fits a new engine to one of these, you should consider & o/e merc unit, it costs a bit more but you get a new turbo and injectors and even the engine oil as well, I wasn’t told this when I first inquired

wish I had have done.

Update

Posted by Christy Doyle on May 20, 2011, 2:37 pm, in reply to "UPDATE."
Message modified by board administrator May 23, 2011, 4:21 pm

Hi,
Have you only got the injector checked from number 4 cylinder or all 4,you say you had them checked initially,does it not seem funny that you would have refitted the "offending" injector on the same cylinder when refitting,have you been given an explanation as to what the injector is doing to cause this problem,( especially when its the same cylinder thats suffering )Just a thought,Regards,Christy.

Re: Update

Posted by Lindsay Flaxmer <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5521' width='330' height='300' border=0 style='border:none;'> on May 25, 2011, 10:25 am, in reply to "Update"
Lindsay Flaxmer

Yes I did think that, I suppose there was a 4 in one chance of fitting that same injector to number 4 cylinder, I will be fitting 4 brand new injectors when the engine returns, but I am still not fully convinced that will be the end of the matter, I have spoken to all sorts of people about this and no one can really assure me, Engine wiring looks good and like I said could it be the ECU? But no one that I have spoken to thinks in could be.

Thanks,
Lindsay.

Re: Update

Posted by Darren Cotton <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT1876' width='330' height='300' border=0 style='border:none;'> on May 25, 2011, 10:14 pm, in reply to "Update "
Darren Cotton

Lindsay

I'd be interested to know how the injector caused this, you say vege can guarantee that the injector is to blame, have you not challenged them for a detailed explanation?

and for it to be same cylinder....

Darren

Fixed #

Posted by Lindsay Flaxmer on October 11, 2011, 6:26 pm, in reply to "Mercedes Benz Sprinter 2.1 2003 - Melted piston, injector failure? #"
Message modified by board administrator October 12, 2011, 1:22 pm

Hi

A belated update on this job I needed to give it some time to make sure all was well.

I eventually got the engine back with the assurance from rebuilders that injector failure had caused the piston to melt.

So I bit the bullet and purchased bran new Mercedes injectors and all seems well at this moment.

The big lesson learnt here for me is I should have insisted on a Merc exchange engine as I have been told that they come with new injectors and new turbo, it’s a pity that the merc parts advisor didn’t tell me this when I priced the job up I think it was about £1400 more than the VEGE unit.

Thanks for your input
Lindsay

« Back to index

[ Diesel Diagnostics ]

Copyright © uk autotalk