*NOW BOOKED FOR 2024* Transitmania 15 @ Santa Pod 19th to 21st July 2024 *ALL DETAILS HERE*


1996 2.5tdi minibus valves hitting pistons

Transit Mk3, 4 & 5(smiley front) Forum. All Transits 1986 - 2000

1996 2.5tdi minibus valves hitting pistons

Postby Hazepurp » Fri May 11, 2018 12:47 pm

Hi all
My engine was turned out of time accidently and four rods bent two rockers.
I have replaced rods n rockers timed it up from TDC according to the haynes manual with all 3 pins locked and engine turns fine until I try to do valve clearances. All exhaust valves hit. ...inlet are ok.
Very confused. .....
Hazepurp
Newbie
 
Posts: 3
Joined: Fri May 11, 2018 12:17 pm

Re: 1996 2.5tdi minibus valves hitting pistons

Postby dumper » Fri May 11, 2018 7:40 pm

The only thing I can think of been wrong you have not pinned it up right or have you set the tappits to the correct clearance and adjusted useing the sequence in the book standard adjustment sequence does not work on a di
MK 8 L4 H3 Motorsport campervan
Past camper vans
1974 mk1 v4 with 2.0 pinto fitted
1986 mk3 2.5 di swb
1990 190 lwb 2.5 di
1998 100 lwb 2.5 di
2006 350 jumbo 135 tdci
dumper
Transit Extremist
Transit Extremist
 
Posts: 5438
Joined: Sun Jan 20, 2008 2:56 pm
Location: Lincolnshire

Re: 1996 2.5tdi minibus valves hitting pistons

Postby ceurieusneus » Fri May 11, 2018 8:18 pm

dumper wrote:The only thing I can think of been wrong you have not pinned it up right or have you set the tappits to the correct clearance and adjusted useing the sequence in the book standard adjustment sequence does not work on a di

Could you tell me, what you mean with standard adjustment sequence?
Thanks!
Writing was not invented to look for spelling errors :wink:
Ford Anglia '62, Mercedes 200 '86, Transit ambulance/camper '88, Mercedes CE300 '89, caravan Puck '75
My ambulance conversion
ceurieusneus
Transit Aficionado
Transit Aficionado
 
Posts: 257
Joined: Sun Feb 01, 2015 5:04 am
Location: Belgium

Re: 1996 2.5tdi minibus valves hitting pistons

Postby gotgcoalman » Fri May 11, 2018 9:28 pm

ceurieusneus wrote:
dumper wrote:The only thing I can think of been wrong you have not pinned it up right or have you set the tappits to the correct clearance and adjusted useing the sequence in the book standard adjustment sequence does not work on a di

Could you tell me, what you mean with standard adjustment sequence?
Thanks!


it's the old rule of 9. Think it was for the 1,3,4,2 firing sequence.
1 open set 8
2 open set 7
3 open set 6
4 open set 5
ne m'écoute pas je suis plein de merde.
A house without a dog is like a forum without a BJT.
Too bloody quiet :shock:
User avatar
gotgcoalman
Transit Extremist
Transit Extremist
 
Posts: 12249
Joined: Thu Jan 22, 2015 6:04 pm
Location: Aycliffe in County Durham

Re: 1996 2.5tdi minibus valves hitting pistons

Postby Chug » Fri May 11, 2018 10:59 pm

The engine turns two complete revolutions without valves hitting and pins fit in again?

Then when you set valve clearances it locks when turning?

What are you setting valve clearances to?

How did the 'accident' happen?
1991(J) twin wheel tipper 2.5di
1994(L) twin wheel tipper 2.5di
Chug
Transit Fanatic
Transit Fanatic
 
Posts: 2438
Joined: Tue Jan 02, 2018 9:27 pm
Location: Tring, Hertfordshire

Re: 1996 2.5tdi minibus valves hitting pistons

Postby ceurieusneus » Sat May 12, 2018 6:54 am

gotgcoalman wrote:
ceurieusneus wrote:
dumper wrote:The only thing I can think of been wrong you have not pinned it up right or have you set the tappits to the correct clearance and adjusted useing the sequence in the book standard adjustment sequence does not work on a di

Could you tell me, what you mean with standard adjustment sequence?
Thanks!


it's the old rule of 9. Think it was for the 1,3,4,2 firing sequence.
1 open set 8
2 open set 7
3 open set 6
4 open set 5


Thanks, this gives me a good idee how they had f....d up the clearance off my outlet valves ... some had more than 1mm :mrgreen: :evil:
I am pretty deaf (sound of big engines) so I run this engine for 2 years, without notice, lucky the MOT man told me. :oops:

Previous, (long time ago) I always used on my cars the "mirror" system.
Writing was not invented to look for spelling errors :wink:
Ford Anglia '62, Mercedes 200 '86, Transit ambulance/camper '88, Mercedes CE300 '89, caravan Puck '75
My ambulance conversion
ceurieusneus
Transit Aficionado
Transit Aficionado
 
Posts: 257
Joined: Sun Feb 01, 2015 5:04 am
Location: Belgium

Re: 1996 2.5tdi minibus valves hitting pistons

Postby dumper » Sat May 12, 2018 7:38 am

Just read my reply and it maybe misleading to set the tappits do not use the 1from 9 Method use the table in the Haynes manual :(
MK 8 L4 H3 Motorsport campervan
Past camper vans
1974 mk1 v4 with 2.0 pinto fitted
1986 mk3 2.5 di swb
1990 190 lwb 2.5 di
1998 100 lwb 2.5 di
2006 350 jumbo 135 tdci
dumper
Transit Extremist
Transit Extremist
 
Posts: 5438
Joined: Sun Jan 20, 2008 2:56 pm
Location: Lincolnshire

Re: 1996 2.5tdi minibus valves hitting pistons

Postby gotgcoalman » Sat May 12, 2018 8:21 am

Correct way........
valve clearances
Inlet 0.20mm
Exhaust 0.38mm

valves fully open valves to adjust

1 and 6................... 4 in and 7 ex
2 and 3................... 5 ex and 8 in
4 and 7....................1 ex and 6 in
5 and 8....................2 in and 3 ex

firing order on a Di is 1,2,4,3
ne m'écoute pas je suis plein de merde.
A house without a dog is like a forum without a BJT.
Too bloody quiet :shock:
User avatar
gotgcoalman
Transit Extremist
Transit Extremist
 
Posts: 12249
Joined: Thu Jan 22, 2015 6:04 pm
Location: Aycliffe in County Durham

Re: 1996 2.5tdi minibus valves hitting pistons

Postby ceurieusneus » Sat May 12, 2018 6:41 pm

Yes Yes,
I was not mislead... not at all 8)
I had set the valve clearance as in the Haynes.
But now, I suspect the previous owner to have used the rule of 9. :(
I can not explain otherwise, why the clearance of the exhaust valves was so enormous... :x
Thank you guys for the explanation. :D
Writing was not invented to look for spelling errors :wink:
Ford Anglia '62, Mercedes 200 '86, Transit ambulance/camper '88, Mercedes CE300 '89, caravan Puck '75
My ambulance conversion
ceurieusneus
Transit Aficionado
Transit Aficionado
 
Posts: 257
Joined: Sun Feb 01, 2015 5:04 am
Location: Belgium

Re: 1996 2.5tdi minibus valves hitting pistons

Postby Hazepurp » Fri Jun 15, 2018 4:51 pm

Hi everyone thank you so much for your replies! I had to go away for a bit re late reply but yes I was a numpty and had mistaken a shallow notch on the flywheel (that did lock the crank) with the actual hole for the pin! All clearances/timing now correct.

Now I have a new problem. .....she turns and turns but will not fire :( I have bled the system and have no fuel leaks but have the noise of air escaping somewhere down the back of the cylinder block I'm still looking for the source. .......but I'm getting despondent now.......any ideas guys? X
Hazepurp
Newbie
 
Posts: 3
Joined: Fri May 11, 2018 12:17 pm

Re: 1996 2.5tdi minibus valves hitting pistons

Postby gotgcoalman » Fri Jun 15, 2018 7:35 pm

so it'll turn over no problem but not fire?
you have fuel up to the injectors?

Charge/use jump leads and squirt wd40 or similar into the air box and see if it tries to start.
have you disturbed any wiring?

the air escaping noise could be a valve issue. valve open on the compression stroke.
check they're set correctly.
ne m'écoute pas je suis plein de merde.
A house without a dog is like a forum without a BJT.
Too bloody quiet :shock:
User avatar
gotgcoalman
Transit Extremist
Transit Extremist
 
Posts: 12249
Joined: Thu Jan 22, 2015 6:04 pm
Location: Aycliffe in County Durham

Re: 1996 2.5tdi minibus valves hitting pistons

Postby Hazepurp » Fri Jun 15, 2018 8:14 pm

Hi
Fuel up to the injectors yes. Wants to fire with brake cleaner in the airbox but stalls immediately.
Checked all wiring ....
When you say check the valves do you mean clearances? It wooshes in time with the pistons. ..Once every four strokes....like a steam engine almost. ...just can't see where from! ...is it sucking air in rather than blowing it out?
Thanks for your time :)
Hazepurp
Newbie
 
Posts: 3
Joined: Fri May 11, 2018 12:17 pm

Re: 1996 2.5tdi minibus valves hitting pistons

Postby vanfox » Fri Jun 15, 2018 8:52 pm

I recall a similar whooshing sound a while back. Check the injector seals. Have you had them out? Are all the securing bolts tight?
vanfox
Transit Fanatic
Transit Fanatic
 
Posts: 2164
Joined: Mon Sep 04, 2006 2:41 pm
Location: Warrington

Re: 1996 2.5tdi minibus valves hitting pistons

Postby gotgcoalman » Sat Jun 16, 2018 11:19 am

Yep could be 1 or more of the valves not closing fully.
+1 on checking injector seals.
squirt some soapy water around the base of each injector and look for bubbles forming.
ne m'écoute pas je suis plein de merde.
A house without a dog is like a forum without a BJT.
Too bloody quiet :shock:
User avatar
gotgcoalman
Transit Extremist
Transit Extremist
 
Posts: 12249
Joined: Thu Jan 22, 2015 6:04 pm
Location: Aycliffe in County Durham


Return to Mk 3, 4 & 5 - Second Generation Transits



Who is online

Users browsing this forum: No registered users

This site contains affiliate links for which we may be compensated.