1999 2.5 TD not starting, blow back from air inlet

[Stefano]

Hello Collective Transit wisdom:

The condensed version of my query:
1999 2.5 Turbo diesel not starting, get blow back diesel mist via the air inlet.
Could the partially torn timing belt (image link below) have "ridden over" the injection pump pulley and thrown the timing out?


The long version of my query:
The Transit is a 1999 2.5 TD (Blue dot on injector pump) 180.000 Kms, LWB, mid roofline,
has ben 1st key-turn starter for ever.

Then suddenly...... one afternoon the guy driving it reported that it kept stalling at idle, and he promptly ran (low speed tap lucky!) in the towbar of the car in front.

No major damage, but no way of starting it since! After towing it home we discovered that one or both of the alternator & Pwr Steer belts had come off and wound themselves very, very, very tightly around the crankshaft pulley (possibly the cause for the stalling at idle)

I replaced both belts, but no start,so then I tested:
Fuel in tank = OK 60% full
Uplift pump = OK strong & fast flow from the filter
Diesel Filter = I replaced it in case it was clogged (no change)
Cracked the injectors = nice & strong squirts of fuel
Purged the lot, then tested return fuel line from injection pump = No air bubbles, but a strong flow of diesel.

A (poor quality) AVI movie of the non starting can be seen at:
http://www.zippyvideos.com/7880610145002426/nostart/

If you see the video above you will notice fumes/smoke wafting past the lens, and its coming from the air inlet ! Yes from the head, back to the manifold and past the airfilter and up to the inlet !!

The fumes (I'm pretty certain) are non-combusted diesel/air mix,

Now methinks that the timing belt is the likely candidate, as we discovered that this belt is split (likely caused when the other belts wound around the crankshaft)

The split in the timing belt can be seen in the image below
http://www.imagehosting.us/index.php?ac ... nt=1334711

Thanks for your help
Stefano

(This is a long post, I realize, if inapproprate, please advise me and excuse my shortcomings in forum etiquette !)

[gemini]

definately needs timing belt replacing and timing checking, it may have jumped and a piston could have hit a valve or the tensioner may have failed

[crazyscoot]

Not sure if its the poor quality sound but that engine sounds tight! Heard any bangs or clattering? Dont try and start it until you know for sure that the timing is correct (this may well be to late)

[rover]

Yep I'm with the other two, get the belt ( and tensioner if it looks/sounds rough) changed before you try to start it again.

If that doesnt cure it then you will need to remove the rocker shaft and pushrods and inspect for damage, if there is a damaged pushrod/rocker then the head will need to come off cos you will almost certainly have a damaged valve or two as well.


Rover.

[madmark]

yep i agree as well get the belt changed asap!

[Stefano]

Thanks Gents (I assume !),

It will be booked in for surgery (aka a new timing belt) tomorrow, I'll post back on the outcome.

By way of thanks, if I can help with diagrams, I have a copy of the Ford TIS (from eBay, so I guess you all have it anyway, but, if not), just ask !

[motorwise]

Stefano

they have a habit of drawing the fan belt into the cam cover if it shreds but they never do any valve damage - if you fancy having a go at it, it's usually just a simple matter of fitting a cam belt kit and replacing the pushrods and finally adjusting the tappets (obviously check the rockers for damage and make sure you recover the displaced thrust pads from the tops of the valves)

simple job should take you no more than about an hour or so - I've done it at the roadside countless times on breakdowns and never had to lift a head once

good luck with it