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Starting issues 3.0 Trooper 4JX1


 
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PaulMag
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Joined: 12 Oct 2015
Posts: 8
Location: Kildare Irleand

PostPosted: Tue Oct 13, 2015 23:49    Post subject: Starting issues 3.0 Trooper 4JX1 Reply with quote

Hi All. This is my first time to post but I have read many posts on the 3.0 trooper starting issues and have to say the site is the best I have come across and the in depth knowledge of members has been a great help. So here it goes on my starting issues on my my recently purchased 04 reg 4JX1.

very hard to start - found out No.3 glow plug was snapped in head/bypassed and the others were suspect. after reading forum thought best to leave it as it was starting. After two weeks, it died completely and would only turn over and not start. Tried the white wire trick and presto started, albeit a bit lumpy. I drove it (cold) 2 minutes till I got it home . Decided to grab the bull by the horns and attack the glow plugs and the replace orps. (again all with help of forum). Removed No.1 and No.4 glow plugs but No.2 broke half way out and as mentioned No. 3 was already broken. Engaged services of a glow plug removal specialist who would remove broken glow plugs on site and requested that I had the inlet manifold removed beforehand. With great difficulty I removed the all manifold bolts, but was unaware of the fuel inlet adaptor needed to be removed and admit I may have man-handled the manifold a bit before realising to remove he adaptor (I did not break the fuel adaptor).

Specialist arrived and removed No.2 and 3 glow plugs, happy days. Reassembled manifold complete with new gasket and started first time, (with white wire disconnected only) ran for about 1 min and turned knocked it off. Decided to drop the oil and change both oil filters, filled with 15/30 fully synthetic and fitted both blue print oil filters. Started again straight away,oil light off, ran for 15 seconds and died. Would not start even with white wire disconnected. Thought pick strainers may faulty, removed sump, all strainers in tact, but changed seal on short pick up. Refitted everything and still no start, added two extra litres of oil, still no start.

Puzzled, I removed dome nut on fuel adaptor to ensure no air lock, gave primer a few pumps and it seemed there was a water/coolant mixed in the diesel. Very strange. I have learned on the forum, of injector sleeve trouble with diesel mixed in coolant or diesel mixed with oil, but not coolant in the fuel.

Possible cracked cylinder head I fear, but would like to pressure test fuel system in the head to confirm.Any ideas

Thanks
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f4lcon
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Joined: 12 Oct 2015
Posts: 9
Location: Hampshire

PostPosted: Wed Oct 14, 2015 8:39    Post subject: Reply with quote

First thing I would do is a compression test
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PaulMag
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Joined: 12 Oct 2015
Posts: 8
Location: Kildare Irleand

PostPosted: Wed Oct 14, 2015 13:02    Post subject: Reply with quote

Thanks F4lcon

Yes it looks like a compression test might be the way to go alright
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eithan h
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Joined: 11 Dec 2005
Posts: 8195
Location: oxfordish

PostPosted: Wed Oct 14, 2015 18:44    Post subject: Reply with quote

if you have put 15/30 oil in it then it's to thick and won't start it needs to be 5/30

coolant in the fuel is common due to the lower o ring on one of the sleeves going, when i do them for diesel in the cooling i always drain the tank as the coolant will end up there as well
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PaulMag
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Joined: 12 Oct 2015
Posts: 8
Location: Kildare Irleand

PostPosted: Wed Oct 14, 2015 22:48    Post subject: Reply with quote

Hello Eithan h

Sorry yes I meant 5/30 fully synthetic not 15/30 I am nearly gone mad with this trooper. Ok Thanks for that, I put a direct fresh diesel feed into head and got it started this evening, checked the coolant and yes there seems to be a strong smell of diesel in the radiator so I think your right Eithan injector sleeves and seals are the main suspect along with a complete drain down of fuel and coolant system.

Is it common for the injector sleeve seals to go when removing tight glow plugs in the head because the seals seemed to be OK before I started the repair of glow plugs, I just fear a cracked head may be the issue and if I go to the trouble of replacing sleeves and seals only to be left with same defect I will be in the mad house.
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eithan h
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Joined: 11 Dec 2005
Posts: 8195
Location: oxfordish

PostPosted: Wed Oct 14, 2015 23:20    Post subject: Reply with quote

No it wouldn't of been from the glow plugs being seized, unfortunately the only way to know is to change the seals and see what happens. 9 out of 10 times it is the seals and it's an easy fix the hard bit is getting the sleeves out as you need a special tool
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PaulMag
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Joined: 12 Oct 2015
Posts: 8
Location: Kildare Irleand

PostPosted: Thu Oct 15, 2015 12:54    Post subject: Reply with quote

Thanks again Eithan, before I gave the direct fuel feed into the head, I fitted a new fuel pipe adaptor along with 3 new washers into the head (just in case it was damaged during manifold removal), so tonight I am going to run it with the direct diesel feed in and collect the diesel from the return pipe to check for water contamination. If still contaminated I will change all the injector sleeve seals and injector washers and along with a new orps, complete flush of coolant and fuel system and hope for the best.
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PaulMag
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Joined: 12 Oct 2015
Posts: 8
Location: Kildare Irleand

PostPosted: Mon Oct 19, 2015 10:50    Post subject: Reply with quote

Hi All

Update as follows: Flushed the fuel tank (badly contaminated fuel and coolant mix),flushed fuel system, and changed the orps.  Started ok, (even without orps calibration) collected the return diesel in a beaker to prevent further contamination of fuel tank, and seen the return diesel also badly contaminated. Going for injector sleeve seals now but fear the fuel/coolant contamination is so bad, that a cracked head is the problem. But for €60 for complete injector sleeve O-ring set, I will chance this first, fingers crossed.
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