2.5 TD No Boost - Wastegate stuck?

[redeemer]

Does the engine makes a clinging noise when decelarating??
I still point at the camshaft, being slipped by one thoot.
If you hear that noise , it maybe the valves just touching the pistons...
Eager to know what will be the fault in this one...

[dark legend]

I'll get the cambelt cover off at the weekend and check the timing out..

[gardener68]

when the red light used to come on with my van the engine sounded very knocky and power fell away dramatically ,it was hard pressed to even get past 35mph and didnt even want to look at going up inclines.

i still rekon you got a fuel supply issue if nothing shows on fault scans

hope you get it sorted mate cause even though im really pleased with my bosch conversion it still doesnt match the smoothness and "right" feel of the epic when its was working properly.
(kick its ass in a drag race though )

[dark legend]

Could the timing belt have slipped

Bingo! Give that man a prize....




That's with the flywheel locked with a 12.5mm drill bit, perfect fit, no play in the crank pulley. It was exactly 1 tooth out (advanced)

Timed it back up with a new belt on this morning and I could tell it had sorted it without even driving, back to a nice quiet sound, could hear the turbo spool up properly. Just come back from a test drive and it's perfect again, pulling like a train!

[dark legend]

Questions:
[*] Is it likely to have damaged anything? Valves etc. It doesn't sound or feel like it's damaged anything, but 1 tooth out on a flat head seems dangerous to me?
[*]Why did it slip? The belt was still tight and the tensioner was tight? It happened on overrun towing a trailer, just as I lifted off on the crest of a hill, i.e it was heavily loaded and then suddenly unloaded. Maybe I have fitted the tensioner incorrectly, i'd better re-read the TIS instructions (although they were pretty crap) Do both bolts need to be tight or are you supposed to leave one slacker to allow for re-tensioning by the spring as the belt stretches? Torque settings?
[*]How come the EPIC didn't fault for it? I would have thought and entire tooth out was excessive timing variation?

[MinorMatt]

If its driving perfectly now nothing will be damaged...

Belts arnt meant to be reused once they have been taken off, which could account for the slippage. Also what type of tensioner have you used? The round one with a single bolt through the middle or the one with a seperate spring and 2 bolts? The latter is "manual" and isnt self adjusting.

I think the EPIC allows for 4 degrees variation, one tooth *may* just been within this range??

[MinorMatt]

Just nipped through your build thread...

you were using an old belt with the old type tensioner. Im not suprised it slipped! The older type tensioner is bolted into place and cant move, therefore if the belt stretches it can get a little slack and jump a tooth. Especially bad with a used belt.

I know you have put a new one on now, but did you use the new type tensioner?

[dark legend]

It's got a big spring in a slot, bolts at one end to the block and has a big washer and bolt through the middle.

[AndyG]

Consider yourself as very lucky

You shouldn't ever re use an old belt once it's been fitted, even if it's just done a few hundred miles (I thought you originally just wanted to try the engine )


viewtopic.php?f=2&t=40506&p=368457&hilit

[dark legend]

I re-fitted to move it around and try it out however the replacement (first one they sent was new wider type) took a few weeks to get sorted out (various reasons)

I needed to use the camper to go racing at our local club.
Couldn't see a problem as long as the old belt was sound (which it was, no cracks or splits) and I had fitted the new tensioner.

Still not sure what properties of a belt that has already been used make it unsuitable to re-use with a new tensioner? Why is it more likely to skip a tooth than if it was still in use or a new belt was fitted?

I'm more concerned it was the way I have fitted the tensioner, which means it could happen again...

[ake]

Any manufacturer of belts will state that a used belt if removed MUST NOT be reused

[dark legend]

Yes, but why?

Or in my case why did it fail like that? If old and stretched you would expect it to be overtensioned by the new tensioner, not undertensioned???

Obviously it doesn't ever make sense to re-use a belt, if you've gone that far you may as well change it, but as said above mine was already off when i realised they had sent the wrong one and I had to be able to move it. Couldn't see it failing by snapping as it was in excellent condition.

[ake]

Its to do with the 'Stretch' of the belt, not entirely sure just know not to do it (I also learnt the hard way)

[AndyG]

The Haynes manual is very good if you can follow what they're saying in regard to fitting the belt

The problem with fitting a used belt with the old style tensioner, is the fact that you are tensioning the belt as though it's new
The belt has already been "service stretched"
So tensioning it as though it's new again, is stressing the belt and risking breaking it

If you check the old belt, you may find a tooth broken on one side

Perhaps it never went on quite correctly in the first place

This is where the Haynes manual tells you to rotate the engine as this allows the tensioner to correct any initial slackness , allowing all the teeth to settle in their groves and tensioner to do it's job Then tighten tensioner before turning engine again, then rechecking the timing

Might just be bad luck, I don't really know

[dark legend]

Just hope that next time my bad luck doesn't result in a load of bent rods

Still, was a nice cheap fix (this time), i was looking at new turbos and bosch pumps to start with there!