Transit mk5 timing belt change fail...

[Nonsense]

Guys today I tried to change my timing belt and tensioner on my transit mk5 2.5d following this guide viewtopic.php?f=18&t=56801. Everything was going ok until I installed the new belt and tried to rotate the flywheel by hand to make sure everything is ok before putting everything back and starting the engine. I tried to rotate it clockwise but it wouldnt move at all and I screwed my wrench pushing harder and harder.. it wouldnt move. Then I tried to start the engine with the starter but nothing happened. What could be the problem please help me...

[Punto443]

Did you remove any timing pins that were installed?

[Nonsense]

Did you remove any timing pins that were installed?

Yes, .I did remove the pins before trying to rotate the flywheel

[gotgcoalman]

even if you pinned it 180 degrees out it should still turn by hand.
in the shallow hole in the flywheel rather than the hole thet goes right through.

Was it just a change or did the old belt snap?

[Nonsense]

The old belt was fine. I think I forgot to pin the injection pump. Could this be the problem? If not should I worry about if its timing is off now even if I didnt rotate anything with the belt off?

[cherniy_chack]

Nonsense,so as not to have problems after the replacement of the belt, you need to fix the flywheel, the camshaft pulley and the injection pump pulley.
You do not seem to have installed the retainer in the camshaft pulley hole?
Under the action of the valve springs, the camshaft turned slightly and the valves rested against the pistons.
It happens.

[Nonsense]

I installed 2 pins on the wheels in front of the engine. I believe they are camahaft and crankshaft pulleys. But forgot about the hole under the fuel fulter that I think also should have been pinned and I think its the injection pump timing pin hole? Sorry for the bad english guys. I earn my living with that van and I f*cked up big time. Any help will be much appreciated

Edit: I just found out I forgot to pin the crankshaft(that pin hole in the back of the engine and below the fuel filter. What would be the damage I have done to the engine and how do I fix it...

[dumper]

Remove the rocker shaft so all the valves are closed re pin fly wheel camshaft and injection pump refit belt check pushrods make sure not bent check rockers if any are damaged replace them then refit it check tappits after removing locking pins while turning engine over by hand at least two complete revaluations then re fit all pins to check timeing is correct then remove pins if all ok and belt tension is correct then start up and see if it revs up ok but only for a few seconds if sounds ok refit all covers belts and radiator fill with coolant and road test

[gotgcoalman]

Take the belt off and this is where you have to play with the pulleys to get the engine to rotate into the right posistion before pinning and re installing the belt.

Once you've found the flywheel hole that goes right through use a 3/8" drive long extension bar as a pin (fits perfectly)

Pin the pump and cam shaft.
re fit belt
Remove all pins and rotate the engine 2 turns by hand.
(Check it's on the firing cycle for #1 piston by watching the rockers)
If nothing stops it rotating re insert the pins to make sure it's still all lined up.
give it a turn on the key and it should fire.

happy days

Beat me to it

[Nonsense]

Thanks for the reply, but how do I synchronize the crankshaft so it can be pinned? Does it matter if I turn the camshaft pulley counter clockwise if the belt is off, because now its stuck and cant go clockwise

[gotgcoalman]

Like I said you have to play with the pulleys to find the sweet spot or as Dumper said take the rocker shaft off.

It can be done.
You need to go forward and backward with the pulleys (crank and cam)

The time involved it's probably easier to loosen the rocker gear re time and reset valves.
valves need checking while you have the cover off anyway.

Just make sure you pin the correct flywheel hole (1 that goes right through)

Next change will take you a leisurly morning/afternoon

[Nonsense]

God bless thank you so much for the help. Tomorrow will try everything and lets hope I didn't brake something.

[vanfox]

Do not turn the crank anticlockwise with the front nut. The oil pump gear is only held by friction with the front pulley nut, there is no key in the crankshaft. You run the risk of loosening the nut and losing the oil pump drive.

[gotgcoalman]

crank has a key way as does the cam pulley.
a little bit of back and forward to allow correct timing is ok.
Are you thinking about the oil pump drive gear on the crank?

Once the timing is correct with the belt fitted and everything tightened then the oil drive gear will be ok.

[dumper]

Can’t remember the exact torque of crankshaft bolt but is very high and takes some undoing long scaffold tube and a lot of force to undo so turning back to line up should not be a problem with the rockers off the only resistance will be compressing air in cylinders