2030 died while driving, now struggles to start

[tbndt2030]

Thanks

I don't come from a mechanical background, although I should have some help for the actual doing of things. Is it possible to get a quick 1-2-3 rundown of checking the cooling?

 

[square1]

Two things ypu mention cause some concern, bubbles in the radiator and watered down old antifreeze. I would pressure test the cooling system for leakdown in addition to checking crankcase & radiator for hints of a carmel colored sludge. Diesels can have cavitation that opens small holes in the cylinder wall. Good antifreeze containing SCA protects against that.

 

[tbndt2030]

The plan that's fomenting is check cooling system, engine overhaul. Non-trivial, but hopefully that'll catch whatever's wrong.

 

[tbndt2030]

Spent yesterday taking it all apart.

Bit of sludge in the head gasket but no holes or tears that I could see. Looked in reasonable condition, TBH.

Found coppery metal shavings in the sump.

 

[tbndt2030]

Coppery metal shavings come from a big end bearing.

http://i.imgur.com/odtPvkI.jpg

 

[square1]

I admire your willingness to dig in to the problem. Myself, I would have analyzed & tested to the point of exhaustion and still might not have found the issue.

 

[Tx Jim]

Are those brgs in your photo rod or main brgs?If main brgs it appears a different block or a line bore is in order.

 

[tbndt2030]

Conrod bearings.

 

[larboc]

Coppery metal shavings come from a big end bearing.

http://i.imgur.com/odtPvkI.jpg

If both of those are from the same rod I'd guess the bearing was really worn out and one of the bearings tucked and spun. Check that rod and journal carefully before putting new bearings in it to make sure it isn't egg shaped from hitting the crank journal without a bearing.
The smoke you saw was probably from hot oil at the bearing while it was going for a ride coming out the breather.

 

[jd110]

In my experience, there is no way the crankshaft isn't trashed with a bearing that looks like that. At the very least, it will need to be turned undersized or replaced.