Smoke, engine stoped now no start.

[pabinlove]

Hi all I have one for all to ponder, to my wife was driving the car and I got a phone call at work, saying your car!
Anyway the problems are, smoke from the engine bay, a kind of growling noise and when she accelerated nothing happened. When engine turned off it wouldn't start.
So anyway here's where I'm at the engine will not turn over due to a clicking noise, when you turn the key all the interior lights go out till you let the key go had a look and it's the starting motor not turning also the smoke is coming from the starting motor. So that's those bits kind of sorted, as for the loss of power I'm at a loss I know the clutch is very worn and needs replacing soon, the pedal is not on the carpet and seams to be working fine could anything have broken off to jam the flywheel or something?
As for the starting motor would it be the starter or is there a solenoid or something? Any help would be most grateful many thanks Paul.

[Chrispb]

Smoke noise loss of power may be an air charge pipe split, is there evidence of oil leaking perhaps dripping onto the undertray.

Is the clicking from the fuse box or starter? clicking relays/starter and lights going out sounds like battery is flat.

Have a look in the battery fuse box for signs of melting/overheating.

Starter and solenoid are combined.

[pabinlove]

Sorry been away working the clicking is from the starting motor along with smoke when you turn the key, the interior lights all go out when key is turned will have a look tomorrow around the battery. Is there a specific side I should look for a split pipe? 

[Chrispb]

Check all the rubber pipes from turbo to intercooler to EGR valve
may be a good idea to check for fault codes as this will also help with boost problems.

[insanitybeard]

What kind of smoke is it? Is it diesel combustion fumes from the engine or is it smoke from something electrical overheating?

Ok, d'oh! Having re-read your original post the smoke is from the starter motor area. Sounds like you need to see if you can still turn the engine over manually from the crankshaft pulley to make sure there isn't something physically jammed somewhere which is causing the starter motor to overheat when you try to start the car. The crankshaft pulley will be hard to turn due to the cylinder compression but if you can't turn it at all or it's really difficult then something's up, if you can't turn it then the next step would be to take the starter motor and or alternator belt off and see if it frees up.

Didn't you have trouble with rough running and noise recently? You said there was a problem with the alternator pulley but could you still have an issue with something being driven by the alternator belt which is binding/ seized increasing the load/ drag on the engine to the point where the starter motor just can't turn the engine over?

[pabinlove]

Hi all yes I replace the alternator clutch pulley last week and everything has been fine. just been outside to the old car put it in gear and rocked it a few times to try and free the starting motor that worked okay it started up, but it was rattling and banging then came to a stop again. When I tried to fire it up again The starter motor was clicking like it was jammed again. Could something be broken on the starter motor and jamming in the flywheel. I will take it off tomorrow and have a look to see if the starter motor is all in one piece. I know the clutch also needs replacing could this have broken anyway and jammed.
Many thanks Paul.

[pabinlove]

Missed abit off I'm looking on the ref. section but cannot find how to take the starter motor off can anybody help me please.

[pabinlove]

Sorry all just to add a bit more when you put a minimal amount of pressure on the clutch pedal and turn the ignition key to fire it up when you hear the clicking from a starter motor I can feel something through the clutch pedal if that's anything to help you good bods find me an answer.

[insanitybeard]

I don't think there is an article in the reference library for starter motor removal as yet, perhaps you could document it if you take yours off? It sounds like the starter might not be disengaging properly from the ring gear on the flywheel, or it's staying energised in which case the solenoid may have had it. I don't think it's too bad a job to remove the starter as long as you can get underneath ok, once the undertray is off (if fitted) the motor is on the front of the gearbox, access isn't bad so once you've disconnected the electrics (and battery!) a few bolts should see the motor off. 

[pabinlove]

Hi all I've managed to find the problem found a few things I didn't want to see
so here's an update in photos.

[pabinlove]

Driver side rear of engine not sure if no.1 or no. 4 😢
Going to miss my baby unless you good bodes know a miracle cure.

[pabinlove]

Some ore if the debris

[insanitybeard]

  Oh......... So the engine block is holed then.......... What's happened, has a connecting rod come through the side of the block or something?!

[pabinlove]

Well parts of the rod yes.

[Chrispb]

Well wasn't expecting that one.
So going right back to your first post your missus said it was making a growling noise, bearing failure due to maybe lack of oil or loss of oil pressure.

Has this engine ever suffered from turbo seal failure (runaway) where the engine ingests it's own oil?

That engine is finished not even worth looking at, you will need to source yourself a good secondhand engine.