ENGINE KNOCKING NOISE !!!! 91 2.4 diesel turbo

[dawn]

Hi, I hope you may be able to help - my surf developed a very loud knocking noise this morning whilst dricing down motorway - it started off as a loud tikcing noise a bit like tappits ?. I slowed down and pulled over - i then decided to drive a third of a mile to my destination and as i got there i lost all power and the noise got louder and car shut down !

I called the aa and they came out - they listened to the noise and immediately said i need a new engine !

the car had oil and has only done 126,000 km with no warning signs at all before the noise developed suddenly.

I now have the vehicle at a garage and they are looking at it - i have enquired about new engines and they are ranging from 750 - 1,100 plus vat.

Is it possible for an engine to go that suddenly - I was in Harlow yesterday up and down motorways with no problem at all ?

Any ideas ? also is it possible to replace parts of an engine if its the big end or do Ineed a whole new engine ?

Any help really appreciated as i dont want to be ripped off

Thanks

Dawn

[marky]

Iff it is the big end bearings they need replacing also possible crank regrind iff its showing wear. its worthwhile replacing a lot of other parts while this is being done new seals etc

[Guest]

Hi, I hope you may be able to help - my surf developed a very loud knocking noise this morning whilst dricing down motorway - it started off as a loud tikcing noise a bit like tappits ?. I slowed down and pulled over - i then decided to drive a third of a mile to my destination and as i got there i lost all power and the noise got louder and car shut down !

I called the aa and they came out - they listened to the noise and immediately said i need a new engine !

the car had oil and has only done 126,000 km with no warning signs at all before the noise developed suddenly.

I now have the vehicle at a garage and they are looking at it - i have enquired about new engines and they are ranging from 750 - 1,100 plus vat.

Is it possible for an engine to go that suddenly - I was in Harlow yesterday up and down motorways with no problem at all ?

Any ideas ? also is it possible to replace parts of an engine if its the big end or do Ineed a whole new engine ?

Any help really appreciated as i dont want to be ripped off

Thanks

Dawn

Dawn.

Ok hopefully this will be helpfull.

There are a number of things that may have caused this and yes an engine can just let go without any warning - and this can be any engine not just Surf or even Diesels.

It could have been any of the following:

Small ends - could explain the ticking noise as it could have been a bit of piston slap as the bearing was going.

Big ends - less likely as it would not tend to sound like tappets when it was going - much more heavy noise accompanied by a large amount of vibration.

Piston ring going which has caused something else to go - possibly big end with the swarf from the broken ring ending in the sump and being picked up by the bottom end.

Main Bearings - unlikely to have caused the ticking noise.

Piston breaking up

Plus a few other possibles.

I think personally that you have broken a piston ring which would account for the loss of power. This has probably taken out either a small end (piston to con rod bearing) or a big end or main bearing. The big end or main bearing would not explain the loss of power - I once drove a Ford Escort around with the big ends gone for 6 months and apart from the noise it still had plenty of go in it.

Yes anything in the engine can be replaced on it's own however any one of the things listed above may cause additional damage. You will most likely find once the engine is stripped down that it may need the bores honed or bored out to cover any damage - this will mean new pistons and rings, small end bearings however the con rods probably are OK (unless it was a small end that went. Big ends and main bearings can be replaced on their own often and the engine does not need to come out for this they can be done from underneath by removing the Sump and Gearbox. Piston replacement would generally require the engine to come out although they can in theory be replaced like the mains from underneath.

The only reason for replacing an engine is if it is uneconomical to repair either because of labour costs to do the rebuild or because too much needs to be replaced.

I hope that this is helpful and I hope you don't get stitched up.

Edit.

Just had another thought which is probably more accurate.

I reckon that you mak have slipped a tooth on the timing belt and the steadily worsening noise was the pistons hitting the valves. This may have broken a valve which would also explain the worsening state of the noise. The reduced power would be the timing being out.

Mind you I may have been right the first time but who knows.

Cheers

[dawn]

Hi

Many Thanks for replys - surf is at the garage now and they are checking thoroughly monday / tuesday as they want to eliminate all things before having to replace engine and they think it may be piston problem ? ( will send them your suggestions)

I will update when I have more news - went to dublin for the weekend and was gutted all weekend about my boy !!

Need to go and hire a ford KA !!!!!!!! cheapest I could find !

Ever hopeful

Dawn X

[dawn]

Just heard that the garage needed to put 4.5 litres of oil in surf to get it at right level ? I only filled it up 3 - 4 weeks before ? Perhaps something blew without me knowing and oil just drained out ?

Level in car indcator seemed ok though ? umless it all happened at once and when noise developed oil came out then ?

I still love my surf but hes definately let me down big time !!!

GOd !!!!!

[Guest]

Just heard that the garage needed to put 4.5 litres of oil in surf to get it at right level ? I only filled it up 3 - 4 weeks before ? Perhaps something blew without me knowing and oil just drained out ?

Level in car indcator seemed ok though ? umless it all happened at once and when noise developed oil came out then ?

I still love my surf but hes definately let me down big time !!!

GOd !!!!!

The 'level gauge' in the car is the oil pressure gauge not an oil level gauge.

I would think thta maybe the noise was caused by something that caused the sudden catastrophic loss of oil as 4.5 litres of oil is almost the full amount (about 5.3 Litres with almost 1 litre being in the filter. Other than that the oil loss could have caused the noise - could be either way. I wonder if the oil filter blew a seal and dumpbed all the oil ?.

Cheers and good luck

[AndyBud]

Dawn, I to am in a similar situation, I live and work in Basingstoke (that is a whole separate issue). On Monday I am driving to work and I hear a tapping coming from under the bonnet, the sound is like the end of a leather belt being tapped gently on a hard surface. I inspected the car but because of the sound I thought the issue was a loose guard tapping the radiator. The next day this noise got louder, I checked the oil level after realising that it was an oil pressure gauge, there was next to no oil in it. I Filled up the oil levels and the tapping noise stopped until you revved the car engine at which point the tapping resumes, there has been no loss of power or vibration.

As in your case my local garage mechanic popped round to my house listened to the engine and said it sounds like the big end has gone and may well need a new engine. The garage said they would contact the guy that normally deals with import vehicles, that was 2 weeks ago, the garage finally got hold of the guy who said that trying to find an engines similar to mine (Surf Q-LN130G - engine model 2L) was like trying to find "rocking horse sh*t" and that it took him 9 months to find the last similar engine. From your post it sounds like your garage is a little more pro-active, is there any chance you can share the name of your garage, or some of the sources where you got engine prices from.

The only info I have been able to find so far are exchange and mart (there are garages that say they will supply and fit a new engine for around £1,200) and this site says it can import used engines (http://www.japaneseengines.co.uk/).

After 2 weeks my anger levels have eased but I am now concerned that I may not be able to get the truck working again, which is a shame as this is the first vehicle I have owned that I absolutely love driving (previous vehicles being punto, 206). This will be an expensive lesson for me in remembering to perform my truck maintenance more regularly.

Hope you get yours repaired

regards

Andy Bud

[TonyN]

Anything but major damage due to low pressure should be rebuildable, there is often no need to toss a new motor in, people are just lazy.

Just to get it working again, minimum expense would be fit a new set of mains and big end bearings and see how it runs, although if doing a proper job, crank should be reground as well, the cam bearings and bores checked

2L, 2LT, 2LT/E are all based around the same block, as are all the UK 2.4 pickup motors.

[Andy W]

Engines

Try these for an engine.

http://www.justhilux.co.uk/main.htm

Andy

[dawn]

Dear all,

Thanks you so much for your help and advice.

The update is :

Injectors taken off and sent away as damaged - asked the question of injector people - could the damage on injectors cause the problem - yes was reply - Garage had them back yesterday put them in and .......... Noise is still there !! GUtted - they have now lifted the head and will let me know Monday.

The noise they describe is a very loud metal on metal noise definate knock and very heavy.

If the head is lifted and damaged would it cause this ?

The garage have been great but next option is full engine at about 1600 - they dont recommend I touch the engines I have enquired about as they dont think I will get proper warranty ? they get them for about 1500 with 12 month warranty and guaranteed below 30,000 miles.

Anyhow will know by end of monday what the outcome is.

Andy I have discovered a fantastic company called "find a part" tel number 01603 767686 you tell them what you need and they email / text to over 200 suppliers who then contact you - within 45 minutes i had 7 engines that I could have next day all with gurantees and 3 of which import direct from japan ranging from 750 - 1000 most had 3 month warranty of 12,000 miles and guaranteed mileage - definately woth a call.

The garage I am using is Kings Motors in Odiham 01256 862221 they have been really helpful.

I will post an update when I have it.

Take care

Dawn

[Pete The Tart]

.

..... Piston replacement would generally require the engine to come out although they can in theory be replaced like the mains from underneath.

Not so, you can replace the pistons from above after lifting the head, dropping the con rod end caps and removing the ring of baked on crud from the top of the cylinder.............yes, I know, the world hates a smartarse!!

[Andy W]

When I had my new engine fitted the garage used find a part and like you say they are very good. I couldn't find out the number though so I shall use them again now I have it thanks! I paid £700 for an english 2LTE + Turbo I would definately recommend them !

Cheers

Andy

[The Duke]

fingers crossed for you dawn!!

[dawn]

Right update.

New engine needed !!

Head dead bottom end dead nothing can be done.

Garage have located engine for 1600 plus vat with 12 month umlimited warranty including turbo etc.

Does this seem a little high ? I have been quoted 1,000 so not sure if they are lumping loads on ?

Absolutely gutted as only had surf 11 months and was only on 126,000 km !!

Note even sure its worth spending the 2,500 it will cost as only paid 6,000 for it last feb ??

I feel like ive been kicked all over and half drowned all at once !

Gutted !!!!

Dawn

[Pete The Tart]

Sorry to hear of your woes Dawn.
Unfortunately thats cars for you, they often seem to cost you an arm and a leg!
If it's any consolation I bought my Surf 2 months ago and so far I've had to spend $2,800 and I still got to dish out another $1400 for new suspension all round! And thats just for the parts! Hopefully my wallet will get to have a breather as it's feeling a bit battered at the moment!

If the rest of your surf is in good nick then get the engine done at least that way you'll end up with a nice truck! And you'll be bigger than 905 of the rest of the traffic