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Thread: Disco 3 2.7TD Piston Meltdown

  1. 26th January 2012, 04:39 PM #1
    John Dorward
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    Disco 3 2.7TD Piston Meltdown

    Hi All, first time writer and not certain if I am on the right track...here goes.
    On a recent trip to Adelaide from Berri my 2.7TD with 147,000 Ks ground to a holt after a normal overtaking manouvre of a semi on an overtaking lane on a hill side. Long story short...it turns out to be an absolutely melted number 2 piston. Looks like a blow torch has been taken to it. It is melted and has ended up fracturing in the centre. Why?. I have ruled out fuel as the remaining fuel in the tank was used in the replacement motor without any issues. I have ruled out injector problems as the same injectors are also in the new motor. This vehicle has never overheated nor shown any signs of impending engine problems. Only issue I ever had was a cracked hose between the intercooler and the turbo which caused much black smoke....around 8 months earlier...and which was repaired pronto. On another note....extended warranties...forget them. My extended warranty will not pay...because we are unable to establish the cause. It seems I have a "consequential loss" clause in mine which they seek to call on...for instance if it was say...an injector...well then the injector is covered...but not the engine!!! This cost me $1,500 for a potential maximum $5,000 payout. And CLAIM DENIED!! Shows you should always read the fine print and...buyer beware. Anyway....any suggestions on the meltdown? Heared of any similar experiences?
    John
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  2. 26th January 2012, 04:50 PM #2
    PAT303
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    So you've blown two motors?. Pat
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  3. 26th January 2012, 05:12 PM #3
    John Dorward
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    Hi Pat, no...onl one...the other problem was fixed as soon as I noticed the black smoke...I did a quick analysis and found the problem and did a temp fix with duct tape...then ordered the part and had it fitted...only one blown engine.....HOPING THIS REPLY IS IN THE CORRECT SPOT...Thanks for the reply!!
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  4. 26th January 2012, 05:22 PM #4
    chazza
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    Possibly too much boost pressure.
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  5. 26th January 2012, 05:36 PM #5
    John Dorward
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    Hi Chazza, yeah possibly...but I don't know why...makes me a bit nervous at present...the second hand engine and turbo has set me back around $14K and I would hate to repeat the experience...particularly when no one knows exactly what has happened...anyway..thanks for your reply...JD
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  6. 26th January 2012, 05:46 PM #6
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    jakeslouw
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    On a petrol engine, I'd say a significantly lean condition on that cylinder.....

    But on the TDV6, with electronic timing and all types of sensors?

    Also, diesels don't mind a lean AFR condition.

    Hmmmm.....

    Incorrect AFR on that cylinder/injector? Maybe that cylinder was down on compression and over-fuelled? The excess diesel would pre-ignite and increase the piston crown temps.

    As for ruling out injectors as they are in the new motor: that's a gamble, considering you haven't yet determined a cause. I'd have them tested regardless. You might be overtaking a semi next week and hear a big bang.....
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  7. 26th January 2012, 06:35 PM #7
    John Dorward
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    Hi Jakeslouw, yeah..thats what I am frightened of. I am going to get this tested at a place with a dyno to see if they can shine the light on the problem....to me it is classic detonation...I was theroising that the thing really came close to meltdown when the hose between the turbo and intercooler cracked...and that for some reason the extra fuel that was pumped in causing the black smoke ...due to the extra air from the cracked hose...favored cylinder 2 for some reason...and that eventually the piston failed because of that....who knows, but..well it is a worry. Thanks for your reply...(I don't know how to do the THANKS...on the reply...but I do appreciate the input!! JD
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  8. 26th January 2012, 06:39 PM #8
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    lambrover
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    I second the above post. Leaking or over fueling injector can create high temps and washing of the bore.

    I would be taking them out and getting them checked.
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  9. 26th January 2012, 06:53 PM #9
    John Dorward
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    Thanks lambrover, this is a good suggestion and possably a huge cost saving....certainly will be on my aganda and soon!!! Guess if the prognosis was an injector my fabuluous warrenty company would pay me around $200!!!!. I am hoping to locate a diesel expert with a dyno not too far away.....thanks///JD
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  10. 26th January 2012, 08:55 PM #10
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    lambrover
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    You need to get the injectors looked at by a good shop that has the equipment. Where do you live. It may cost about a grand to get done but that is cheap insurance really.
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