The Iveco "TANK"

[Keith Morris]

I am back on the road as from yesterday with a full rebuild engine in the "Leisure Seeker" and around $15,000 less in my ready available funds. Coles have Weis Bars on Special ($5.00) but I missed out on that as I only did a quick fresh/perishable shop at Farmer Jacks.
I have posted a rather lengthy post on my Injector matter for general interest-- You will need a nice hot cuppa and a scone to get through it. The outcome is that the injector repairer will not accept any liability and maintains that this was caused by a pre-existing problem.
IVECO INJECTOR FAILURE-SEQUENCE OF EVENTS.

On considering the diesel and oil consumption to date, and the distance driven over the period I have owned this motorhome, it is my opinion that the work done on the injectors has caused or greatly contributed to the engine failure and I list the sequence of events for consideration and evaluation. ***note: Saturday, 1st August 2015 entry.

Tuesday 21 July 2015:

[Skippers Trucks fitted Air Horns. Speedo reading 141,143 km].

United Injectors inspected my concern of slight puff of white smoke from exhaust after short period of idle when revs first increased. I asked the mechanic to run Computer Diagnostic for fault codes. The mechanic did not have correct plug and he would try to obtain one on Saturday (25 July) and as the workshop was very busy he booked in for me to return on Tuesday, 28th July.

Tuesday 28 July 2015: Speedo reading 141,525 km].

I arrived at United Injector premises at 08:00am. The mechanic informed me that they had not obtained the on-board computer plug. The mechanic told me that four new injectors would be about the same cost and could be air bagged from the supplier to arrive the next morning (Wednesday) so I gave the go-ahead to obtain and fit new injectors.

The Service Manager told me that the workshop was very busy, and asked if I could come back on Thursday for the work to be completed. This delay was inconvenient to me as I was living in the motorhome with my dog and I had no other accommodation. It was agreed that I could remain in the motorhome overnight with my dog, parked in United Injectors secure/locked premises.

Wednesday 29th July 2015:

The new injectors did not arrive by air-bag as expected and they had not been dispatched from the supplier. (Bosch in Melbourne). I was told that the existing injectors would be serviced and refitted.
After removing and testing the injectors, I was informed that 3 of the 4 injectors had failed the test and needed replacing at a cost of (quoted ) $2,300.00.
With no alternative option, I agreed to the reconditioning of the existing injectors to have the vehicle servicable again in the shortest possible time.

Thursday 30th July 2015:

After some delay with the servicing the injectors were fitted and the engine was road tested for a short drive of a few kilometers around the local area.
I paid the invoice amount of $2,2007.00, allowing a discount due to the time taken for the work to be completed. I decided to return to my residence at Wyalkatchem to load the on-road fresh food supplies for my extended trip around Australia.

I refueled with diesel at Shell Midland, and after driving approx 92 km on the Toodjay-Goomalling road the oil warning light came on, and the injector warning light started flashing. I stopped the vehicle on the [narrow] roadside and checked the oil. The dipstick was showing just below the min mark. I called the Service Manager (Mr. Retief) at United Injectors and told him of this problem.

Mr. Retif suggested that I drive the motorhome to Toodjay and park in the caravan park as he had a contact mechanic in that area. It would be difficult for me to turn the motorhome around on the narrow section of the road in the very heavy rain, it was decided that I would continue driving (about the same distance-about 20+ km.) to the Caravan Park at Goomalling, which I did after filling the oil level to the max mark on the dipstick.

Friday, 31st July 2015:
I phoned Mr. Retif at 08:30am and he arranged for Joel Carr from Carr's Automotive, Goomalling to attend me at the caravan park and inspect the motor fault. Joel arrived just after 09:00am and on looking at the engine it was found that there was very little oil in the sump.
Joel added oil and had me drive to his workshop where he could make a more detail inspection.

Carr's mechanic found that oil was being blown out of the motor from the oil filler pipe, and that there was a lot of smoke from the breather when the filler cap was in place, indication a pressure in the sump possibly from a blown or cracked piston, which he thought was from an injector over-fuelling and causing a piston crack or meltdown.

Joel reported his findings with United Injectors by phone call to Mr. Retif. I drove the motorhome (at a slow speed) to my residence in Wyalkatchem after Joel refilled the oil level.

Saturday, 1st August 2015:

I phoned Mr. Retif this morning and told him of my findings that the diesel consumption had esculated from approx 17 litres per 100 km to over 50 litres for the 180 km driving, and that the engine had used over 10 litres of oil driving the same distance.

I consider that this oil and diesel problem is a result of [one or more] injector failure. Mr. Retif argeed to have the motorhome transported to Skippers Trucks Workshops at Welshpool where the dasmage could be inspected and evaluated.
I obtained a quote of $880.00 incl GST, from Northam Towing to convey the vehicle to Skippers yard. Mr. Retif said thast he would obtain further quotes from other transport companies and contact me when he had the quotes.
I informed Mr. Retif that due to my age and medical condition, I would need several days to unload my effects and food supplies before towing the motorhome. After 10 days had elapsed Mr. Retif had not obtained any quotes. He told me to go ahead and contact Northam Towing to arrange getting the motorhome to Skippers Trucks for inspection/repair.

Monday, 10th August 2015:

Northam Towing uploaded the motorhome at 9am this morning for delivery to Skippers Trucks, Welshpool.
I now await a report on the condition of the engine and a quote for the repairs after their inspection of the engine and testing of the injectors.

[Dot]

You have your MH back in working order, Mr Russell is a happy chappie and you are freezing your goolies off down there so pack up the MH with the bare necessities and head to warmer parts asap.

[Keith Morris]

You have your MH back in working order, Mr Russell is a happy chappie and you are freezing your goolies off down there so pack up the MH with the bare necessities and head to warmer parts asap.

"tanks" here Dot,
I'm thinking about doing that, but first I have several strong letters to write and a few forms to complete and post to the authority in relation to the Iveco bungle.
We are having a 31 c degree day on Thursday--Happy Springtime--get ready for rain over the next few days as the Dowerin Lake has turned pink which means that we have rain within a few days.
I could do a rush trip to Geraldton to visit you and George if there is a hot scone and strawberry jam with cream on offer.
Keith.

[Busman]

But what I want to know is what was found when the engine was disassembled ? Surely the cause could them be pinpointed ?
William

[Keith Morris]

"tanks" here-- Hi Busman,

What the injector mob claim is that the injectors had been leaking for some time previous to them doing the repairs and that caused the damage to the engine. Possibly by long static idle to run the air-con. I pointed out that the onboard 4 kva Odon Generator would be used for this. It was a most unusual circumstance that an IVECO with only 141,000 km would have such a major engine problem. Another claim was that the diesel fuel had been contaminated and I mentioned that with all of the filters in the Iveco that I doubted this as the cause.
I do not accept the findings and reasons put forward, and I feel that there is some liability due to the injector repair company.
On inspection by Skippers Trucks: The main damage was caused to # 2 piston/cylinder. Their quote was to skim the bore and replace just one piston etc however the a large part of the cost was labour to dismantle the enging, so it was advised to rebuild the entire thing while the motor was dismantled.
The quote to repair just the one cylinder/piston etc was over $7,000; so I went the fix it all route and had a complete engine rebuild. The block was sleeved, and the head was machined , all bearings were replaced as was the timing belt and tensioner, plus new other things were fitted as part of the rebuild. That way Skippers were able go give me a warranty on the work and parts.

Skippers Trucks saved the offending piston and the bearings for me.

I must mention the assistance given to me by our Forum Member "PET-ELS". Peter was parked up at my place at the time.
Peter did not hesitate in offering to drive me [and "Russell"] to Perth to get the Iveco back after the repairs were completed. My problem was that even as I have several vehicles in my driveway which I could have driven to Perth, I can not drive two vehicles at the same time.
I also thank those Forum Members who have taken an interest in the matter, and offered me advise of a mechanical nature which I am acting on. WA Consumer Protection are involved now so it's a matter of wait and hurry up, and don't expect any great results, but I have nothing to loose by taking this action. In the mean time; I have a little more confidence in the vehicle now that it has had the engine rebuilt.
Keith.

[Wilbor]

Good luck with your travels Tanks, I hope you have no more worries, just good times

[dapope]

Thats a very bad luck run Keith, I really hope you have no more grief with it. Pretty sure you would have picked up any damage earlier if it was prior to the injectors being reconditioned. ..

[generdawg]

WA Consumer Protection are involved ... I have nothing to loose by taking this action.

That may be true, but you do have the satisfaction that this will cost someone time and effort to just show up defending themselves and it goes on record in their file should anyone ask if there are any judgements or matters pending against this mob. Legitimate businesses care about negative feedback.

dawg

[Busman]

What about a test of the old reconditioned injectors by another injector rebuilder ?
William

[Keith Morris]

What about a test of the old reconditioned injectors by another injector rebuilder ?
William

"tanks" here---Busman,
this was done by Skippers Trucks who had R.Moore & Co do an independent test before they gave the injectors back to United Fuel to conduct their own tests. R.Moore found that the injector test was to specs.
Keith.