by nigelwheeler » Sun Oct 23, 2022 7:54 pm
Hi folks - just to clarify, the key slot / end of the shaft is completely destroyed, so it's not just a case of replacing the key.
I didn't turn the pulley nut, but I have no doubt it was probably something I did when changing the belt and timing up - I probably did try to turn the cam position back ever so slightly and that maybe loosened the nut. Also, when the engine had stopped I tried to start it again before I then tried turning over by hand and realising it had got stuck .
One thing I did notice is that one of the rockers is extremely stiff, so that could have been a contributing factor, and will need changing.
I guess the cam shaft itself could also be broken, although no way to really tell without accessing it directly as I can't turn it over.
Thanks for all the comments, the most encouraging of which is that I should be able to replace the camshaft without removing the engine from the vehicle, by providing access having removet the sump. Any further advice on that procedure would be great.
I'm also looking at the possibility of just swapping the whole engine out and then working on rebuilding current one out of vehicle. There's a 1992 2.5 Di banana available locally, and the other possibility is stripping the cam shaft & sprocket from this for parts rather that finding new, although not sure everything will be compatible due to age, or the wear will be an issue.
I realise I'm making myself sound pretty incompetent here, but I do have some experience with diesel engine internals, and things normally go very well. I kinda wished I never touched the timing belt but thought it was best practice to do it at the same time as the pump. I mainly messed up by not loosening the pump sprocket so the belt could settle properly and then started stupidly fiddling when it was all timed up after cranking round twice and checking. I really don't want to lose the van just because of the bad economics of my own stupid mistake (although I also really I it daily for work so having to probably take on a slightly newer Mk6 in the meantime) so all the help and advice to get me back up and running again myself at minimum expense is hugely appreciated! [Rambling ends]