Which Gearbox + Other issue

[metalworker0]

The offending pipe ..looks exactly the same as mine ..........

oil leaks out of the joint on the boost pipe (the large stiff plastic pipes) and runs down and drips onto vacuum pipe underneath, it then collects around this pipe where it comes off brake vacuum booster.

this oil lives in the booster pipes and is a feature of most ford turbo diesel engines. WARNING THOUGH.. excessive oil can mean turbo failure ----- most connect 1.8s seem to have this drip though ..nothing to do with turbo failure in most cases.



The boost pipes and intercooler accumulate the oil ........which has to be cleaned out every service by dismantling everything, the older and more worn it gets the more oil ..i suppose.

I don't know if this oil clears itself out if you thrash the thing ....as i only trundle round in mine. never doing over 2500 revs, especially since the 20mph speed limit here in wales

to perform a a boost pipe and intercooler service .

But if you ask me ...myself ...
The following is a a job that should be done on these vans at least every couple of years or 15,000 miles, what ever comes first.

I would be taking all the pipework off including intercooler ..and giving it all a really good clean inside and out ..during the clean you can inspect each piece individually for damage or cracks..or rubber sealing gaskets ..ripped, torn , deformed etc ...
What you will find ------- lots of oily gunge..
I use very strong solution of biological washing powder...sort of 1 cup full to every pint of boiling water ..intercooler has to be taken out...it will probably take 2- 3 pints

Block one end . Rags, towel, plastic bag and elastic band ..pour it in. then let stand for five mins ...shake it ..pour it out and flush with hose.

You could use paraffin , Jizer or petrol ..but that would be far more expensive than cheap Lidl / Aldi or Home Bargains washing powder.

other people with the same problems (not many here) install "catch cans" between the pcv (right hand of cylinder head ) and the boost pipe. which will also lessen the accumulation of gunge in the EGR and inlet manifold which can cause problems after a while.


all the best.mark

[AstraToConnect]

Excellent info again really appreciate it, Suppose before i make a start i should go find out if its chain or belt save wasted coolant and oil doing it all again if i need to replace anything on the timing.

[AstraToConnect]

So my engine Code is R2PA will this for sure have a wetbelt ? or should i call ford and ask them

[metalworker0]

i haven't got an answer for that ..

Story here somewhere ..that even the dealerships did not know a that the connects had wet belts that had been fitted until sometime after. and other stories that when asked such a question they didn't know.

all the best.mark

[AstraToConnect]

Thanks again mark the strip down begins soon

[AstraToConnect]

Just to add to this i see some Videos miss this step. Would it be good practice to replace the gasket behind the lower timing case also... I noticed i have a bunch of build up bottom left and looks like i might need to do this gasket. OE ref number: 1078522 . Any thoughts on doing this while im in there ?

[metalworker0]

There is a post here somewhere , i think about this gasket , ill try and find it

all the best.mark

[metalworker0]

viewtopic.php?f=54&t=228247&p=1848874#p1848874

all the best.mark

[AstraToConnect]

Thank you boss you guys are very helpful and very quick

[AstraToConnect]

This was an email response i got from Ford

Thanks for contacting the Ford Customer Services Team.

After checking this within our catalogue, I can see the description of this is listed as Belt/chain - Timing, Cassette with belt, and the following part number is listed as compatible:

1562244 -BELT/CHAIN - TIMING, CASSETTE WITH BELT - Ford ENGINE TIMING CHAIN CASSETTE - 1562244



Not sure if this is them telling me its a chain or a belt pretty confusing response but they linked The chain part number twice.
Either way I'm stripping it down

[metalworker0]

whats even more confusing is ford show this part number 1562244 described as:_ "ENGINE TIMING CHAIN CASSETTE"...but show a belt in the picture

https://shop.ford.co.uk/products/engine ... n-cassette

for 1562244 ebay vendors show both

and also some show conversion kits from belt to chain with 1562244 in the title

and just in you've forgotten or missed -

You don't have to strip it down, just take the tensioner bolt out and it will reveal all . but first i think you have to remove the power steering pump .

from 9 mins 55 seconds into video - Allan explains the difference in tensioner bolts between wet belt and chain
https://www.youtube.com/watch?v=-l6-JUImJQw


With engine in situ - How hard it is to get to the stage of pulling this bolt out, i don't know .


all the best.mark

[AstraToConnect]

Yeah i had a quick glance at what was stopping me from getting to the tensioner...Raining here on n off loads here lately so waiting for a decent day. Thanks again.

Il start throwing up some pictures as soon as i can get started.

In the mean time ill Take off what ever pipes for the intercooler and other things give them all a good clean, But carefully as the left side pipe has a sensor on it.
Give the engine a good spray down with some kind of degreaser. Did notice a small drip forming from the Oil filter where the rubber O RING is not sure if its directly from that or something above it quite yet but possibly hasn't been fitted correctly. Hopefully not been put on dodgy and stripped any threads.