Stranded after timing belt snapped

[dumper]

When you set the belt tension did you shaken off the 4 nuts on the pump drive if not it can knock the pump timing by a degree or two

[meerkatmag]

That must be it, it went straight on without needing to undo the bolts. I should be able to correct it by adjusting the pulley position if it's just a few degrees right? I think it might be too advanced actually as it's running better when I get going. Lower temps and seems to have more power. Only issue is smoke when cold. Ill see if I can nudge it a few degrees retarded and see if it helps.

[dumper]

I played about with the timing on my mk3 with it so far advanced it sound like a bag of nails if it’s quieter it may be ok

[meerkatmag]

just wanted to update incase anyone was wondering what happened.

There was a lot of smoke on first startup with new belt, smelled like unburnt diesel. Gradually faded as the engine warmed up. It ran fine, no noticeable issues/noises or power loss. I thought I would just go for it and have driven it almost all the way back to UK now and it's still running fine. I think it must be a bent or sticking valve in cylinder 1, if I crack open the fuel line for 1 the smoke goes away instantly. I don't think I got the valve clearances wrong, as it improves with warmup. Surely if I set it too tight it would worsen with heat? and sound from rockers is normal. Also, there was a knocking sound coming from the exhaust when I first started it. Not noticeable in the engine bay, didn't sound like anything from the rockers. So I think that was the piston tapping the valve back down, having gotten stuck open. After a few hundred miles the tapping noise has gone away and it starts better - still smoky, but not nearly as bad.

I'm planning to take the head off and inspect the valves once I get back. But I'm not going to mess with it now as it's working.

I've got a crazy plan to switch the cylinder head for a mk5 one and install 115hp pencil injectors. Currently have the old chunky ones which are stuck fast in the head. Any reason a mk5 head wouldn't fit a mk3 block? I'm thinking this might be the easiest (and most fun) way to fix it rather than try to replace valves and guides.

All advice massively appreciated! I'm making a little video of the incident if anyone is interested let me know I'll post it.

[Harvy]

I’m glad to hear you are nearly back. It sounds like a proper adventure! Where are you now? I can’t offer any constructive information as I know nothing about your mark of transit, but I would certainly watch the video.

[MinorMatt]

IS the engine a turbo?

[meerkatmag]

Yes and it has an intercooler and bosch 146 pump.

[MinorMatt]

Yes and it has an intercooler and bosch 146 pump.

Thats the answer then - the timing is too retarded. No need to remove the cambelt -but slacken the 4 bolts on the front of the pulley, advance the timing to the end of the slots and re-tighten

[meerkatmag]

It was originally a na engine with lucas cav pump. Bosch pump was fitted with turbo. I thought in this configuration you kept it pinned? I have checked timing and pins all go in easily. I will try advancing if you think it's worth a shot? But I think there's a problem with cylinder 1 valves. If I crack fuel pipe to 1 then the smoke completely clears. Other cylinders have no effect. So I think low compression on 1.

[Chug]

Try swapping the injectors round see if it changes cyl.
And no harm in trying advancing the timing.

[dumper]

Good luck on getting the injectors out on yours you can use a slide hammer I cut a injector pipe and welded a nut to the nut off the pipe to fit my slide hammer on to the injector threads worked ok on 1 to 3 but for number 4 I had use a pice of angle iron and a bolt to make up a fulcrum to clear the scuttle of the van .
The pencil injectors are a real pain I even ordered the correct tool from Ford and broke it on number 4 I ran the van with it without the clamp for weeks and used loads of WD 40 but it wouldn’t come out when foot and mouth shut motorsport down I decided it was coming out even if it snapped off and the head had to come off it did off with the head only to find 4 cracked pistons .

[meerkatmag]

Here's my video of the trip including breakdown: https://www.youtube.com/watch?v=tzEiJ1oN3eE

Appreciate all the help I an back home now!

[dumper]

Good old DI it’s now earned a GB sticker we use get one at work if you repaired a BrakeDown on the side of the road and didn’t need a recovery truck it this case GB was for got back .
Just a point on the smoke on your YouTube post on my mk3 trying to get a bit more power non turbo Bosch pump I advanced the timing on cold start with the wax stat for cold starting working that also advanced the timing for cold staring it smoked and ratted like yours until up to temperature and the wax stat put the pump back into normal driving mode I had too put the timing back to standard

[meerkatmag]

Good old DI it’s now earned a GB sticker we use get one at work if you repaired a BrakeDown on the side of the road and didn’t need a recovery truck it this case GB was for got back .
Just a point on the smoke on your YouTube post on my mk3 trying to get a bit more power non turbo Bosch pump I advanced the timing on cold start with the wax stat for cold starting working that also advanced the timing for cold staring it smoked and ratted like yours until up to temperature and the wax stat put the pump back into normal driving mode I had too put the timing back to standard

Haha ill grab a GB sticker for sure.

Im going to mess with the timing and see if it has any effect. Im pretty sure it ran pinned before this so it seems strange. My bosch pump doesn't have any cable system for cold start so I don't think I can manually adjust it.

[MinorMatt]

Good luck on getting the injectors out on yours you can use a slide hammer I cut a injector pipe and welded a nut to the nut off the pipe to fit my slide hammer on to the injector threads worked ok on 1 to 3 but for number 4 I had use a pice of angle iron and a bolt to make up a fulcrum to clear the scuttle of the van .
The pencil injectors are a real pain I even ordered the correct tool from Ford and broke it on number 4 I ran the van with it without the clamp for weeks and used loads of WD 40 but it wouldn’t come out when foot and mouth shut motorsport down I decided it was coming out even if it snapped off and the head had to come off it did off with the head only to find 4 cracked pistons .

Yes that does happen... I've had it myself but the vast majorty of injectors put pull out after a quick twist. (I had one which scrapped the head as the injector body pulled apart before releasing). A lump hammer and drift couldn't get it out either!