G'day.
Having an issue with a C9 9dg On-Highway engine within a BCI bus. Hoping some of you on here may be able to give some pointers to the following issue:
The issue: is that the engine is misfiring when warm around the 1000-1500rpm range when increasing rev and billowing white smoke of unburnt diesel (can smell the unburnt fuel).
Engine background: The engine has just been rebuilt (new injector sleeves, reusing original injectors, reusing heui pump). Part of the issue for the rebuild was the bus running rough, billowing smoke and breathing heavy. All bearings were worn, cyl 2 and 6 pistons had cracked skirting and cyl 4 had a cracked ring. New bearings, pistons/liners assisted in rectifying the breathing heavy saga. Boss didn't want to replace injectors just test them when engine is back up and running. The engine ran a dream when first started until it warmed up then started spluttering. In this we found the turbo malfunctioning and also sending oil through exhaust so turbo was changed. Rectified that part of problem but engine still spluttering when putting foot on throttle increasing idle to that 1000-1500rpm range when warm, no issue cold.
What has been done: had diagnostics person come out with CAT ET computer and check for codes, run cyl cut out tests etc. No fault codes, no engine light on dash and his cylinder cut out test showed cyl 1 2 3 an issue. To ensure cylinders injectors were swapped 1>6 6>1, 2>5 5>2, 3>4 4>3. Re ran diagnostics and issue still remained at cyl 1 2 3 according to the bloke using the ET diagnostics system. All fuel pressures and what not in spec.
The following sensors have been changed: throttle position, speed/timing, coolant temp, injection actuation sensor, atmospheric pressure, fuel regulation (including cleaning out the lines). Even swapped the ECM from another bus with no issues to rule out ECM and inspected all wiring which was all good. Fuel filters were changed and did appear to have metal in them. Boss is still adament that the injectors and heui pump aren't the issues but being the only components that do have mechanical components that wear inside them we feel that they are.
We're getting to the last legs of our process of elimination and hoping someone here may shed some light on the issues we're having and what else could be cause... the bloke who comes with the CAT ET diagnostics isn't really much a help....
Thanks.
Having an issue with a C9 9dg On-Highway engine within a BCI bus. Hoping some of you on here may be able to give some pointers to the following issue:
The issue: is that the engine is misfiring when warm around the 1000-1500rpm range when increasing rev and billowing white smoke of unburnt diesel (can smell the unburnt fuel).
Engine background: The engine has just been rebuilt (new injector sleeves, reusing original injectors, reusing heui pump). Part of the issue for the rebuild was the bus running rough, billowing smoke and breathing heavy. All bearings were worn, cyl 2 and 6 pistons had cracked skirting and cyl 4 had a cracked ring. New bearings, pistons/liners assisted in rectifying the breathing heavy saga. Boss didn't want to replace injectors just test them when engine is back up and running. The engine ran a dream when first started until it warmed up then started spluttering. In this we found the turbo malfunctioning and also sending oil through exhaust so turbo was changed. Rectified that part of problem but engine still spluttering when putting foot on throttle increasing idle to that 1000-1500rpm range when warm, no issue cold.
What has been done: had diagnostics person come out with CAT ET computer and check for codes, run cyl cut out tests etc. No fault codes, no engine light on dash and his cylinder cut out test showed cyl 1 2 3 an issue. To ensure cylinders injectors were swapped 1>6 6>1, 2>5 5>2, 3>4 4>3. Re ran diagnostics and issue still remained at cyl 1 2 3 according to the bloke using the ET diagnostics system. All fuel pressures and what not in spec.
The following sensors have been changed: throttle position, speed/timing, coolant temp, injection actuation sensor, atmospheric pressure, fuel regulation (including cleaning out the lines). Even swapped the ECM from another bus with no issues to rule out ECM and inspected all wiring which was all good. Fuel filters were changed and did appear to have metal in them. Boss is still adament that the injectors and heui pump aren't the issues but being the only components that do have mechanical components that wear inside them we feel that they are.
We're getting to the last legs of our process of elimination and hoping someone here may shed some light on the issues we're having and what else could be cause... the bloke who comes with the CAT ET diagnostics isn't really much a help....
Thanks.
