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greenkit · 06-09-2009

Firstly, thanks to all who contribute to this site: as a new Mule owner, I find it essential reading..... I'd appreciate some advice on my engine, the normal FD620D.

I just acquired this 1999 model, service history unknown (but dubious if much care was taken). I noticed overheating when I first drove it (dash light came on), the oil was greyish and way above the max level on the dipstick. The oil filler cap also had grey scum. The engine starts fine and runs well, however. There's no water vapour / white smoke from the exhaust, but a definite puffing from the oil filler cap and the dipstick access hole when running.

I've done a compression test with the engine warmed up, plugs out, and coil supplies disconnected. Turning over as per normal key start, gas pedal at ‘idle’ (min throttle) gave about 115 lb. Repeating with 3-4 squirts of clean oil into the cylinders gave 170 psi. Both cylinders are similar, within a few lb pressure.

I changed the oil and let the engine run, topping up the coolant as per the manual to get the air out: no severe bubbling at the rad filler cap and good circulation through the radiator, fan coming on, etc. A little oily scum at the rad neck, but nothing serious. Tried repeating this for a few days as the coolant fell slightly overnight. Today, BIG problems as the water pump now has a severe leak down the outer crankcase (not noticed previously) and the 'oil' is like milk with dipstick level rising fast.

So, I need a water-pump and probably have piston-ring problems. Do the compression values also indicate leaky head gaskets? Is it likely that the water pump has been the culprit from a while back, allowing coolant to pass into the crankcase / creating an airlock? The 'oil' currently present certainly won't provide much lubrication / ring sealing. Complete rebuild?

Sorry for the long post.....

06-09-2009	#1 (permalink)
greenkit Newbie Join Date: Jun 2009 Posts: 16	2500 mule overheating effects? Firstly, thanks to all who contribute to this site: as a new Mule owner, I find it essential reading..... I'd appreciate some advice on my engine, the normal FD620D. I just acquired this 1999 model, service history unknown (but dubious if much care was taken). I noticed overheating when I first drove it (dash light came on), the oil was greyish and way above the max level on the dipstick. The oil filler cap also had grey scum. The engine starts fine and runs well, however. There's no water vapour / white smoke from the exhaust, but a definite puffing from the oil filler cap and the dipstick access hole when running. I've done a compression test with the engine warmed up, plugs out, and coil supplies disconnected. Turning over as per normal key start, gas pedal at ‘idle’ (min throttle) gave about 115 lb. Repeating with 3-4 squirts of clean oil into the cylinders gave 170 psi. Both cylinders are similar, within a few lb pressure. I changed the oil and let the engine run, topping up the coolant as per the manual to get the air out: no severe bubbling at the rad filler cap and good circulation through the radiator, fan coming on, etc. A little oily scum at the rad neck, but nothing serious. Tried repeating this for a few days as the coolant fell slightly overnight. Today, BIG problems as the water pump now has a severe leak down the outer crankcase (not noticed previously) and the 'oil' is like milk with dipstick level rising fast. So, I need a water-pump and probably have piston-ring problems. Do the compression values also indicate leaky head gaskets? Is it likely that the water pump has been the culprit from a while back, allowing coolant to pass into the crankcase / creating an airlock? The 'oil' currently present certainly won't provide much lubrication / ring sealing. Complete rebuild? Sorry for the long post.....