Major engine problems

[Big_Andy]

Hi all. Long story, but feel all details are needed. About 2 weeks ago, on the Friday of that awful weather (in the North East at least), I was driving up to Washington from Redcar (about 45 miles) on the A19. I noticed nearing the end of the journey that the engine seemed to be spluttering when accelerating, but put this down to the weather (I guess too much driving petrol cars like Minis to think this shouldn't happen). As I came off the A19 to head over to Washington, the engine suddenly spluttered and died (also noticed it rattled like sticking a screwdriver into a fan), and I quickly knocked it out of gear to cruise to a halt. Quick diagnosis of problem led me to think battery/starter motor was dead as couldn't get it to turn over, and as stuck on (very) busy slip road, I called RAC to help (useful that I'd taken my 2 and 3 year olds to give wife a break and give them an adventure as RAC arrived within 30 mins as an emergency).

Mechanic tried to start van with booster pack, then decided to tow me to nearby Travelodge type place where he tried jumping battery direct off his van. He then got a spanner out and tried to turn engine by hand, then got me and mate to help push van in gear before finally declaring the engine had siezed. On investigating oil and water, he declared everything was normal, right levels, no burning smell to oil, noe oil in water or water in oil, she'd simply sieized. He removed a couple of bolts on timing cover to check belt, which seems fine, and floated possibility of loose adjuster causing belt to skip a tooth or two. He said if I was lucky, I would have bent a push rod or two, which could be straightened, and that there shouldn't be too much expense to repair if I took it on myself.

With images of bent valves, etc, and being surprised that design of engine is kind of like an altered old Escort OHV (which I used to rally 20 years ago), today I set about pulling off the rocker cover and timing belt cover (still to come off as 2 bolts rusted up and need to pull pulley for water pump off). I was surprised (happilly) to find all valves level when I took rocker assembly off, but then shocked to find that the follower, cap and spring just came off on valve 7 (second from back) , and realised there were no collets from it anywhere in sight. The valve does just lift back into place, but obviously slips back down when released.

My plan is to continue stripping the TB cover off tomorrow and see if the timing belt is fine, then remove the head over the weekend and hope to find the collets somewhere near the cam followers/cam housing. Am I right in thinking I might need to drain oil/take sump off to find these collets, and that I shouldn't risk running it with them lost inside the engine? (I know, obvious answer there, but it's late and 2 year old daughter only just fell asleep - god I hope I don't need to strip the whole engine down). I bought the van at about 139000 miles in March, and only done about 4000 miles this summer, with a full service in June before driving over to Northern Ireland and back, and thought about replacing the TB then, but time, lack of cash and thinking that company who had owned it before me would have had it done at 120k service.

What does anyone think? Worth carrying on or better to get hold of second hand engine? Any potential problems to face when pulling head off? Tranny is an R reg 1997 17 seater minibus (reduced to 8 + driver and thinking of removing single seat in back) with 2.5D 'banana' manifold engine (used as family transport as I have 4 kids and we participate in historical displays which requires us to have a lot of equipment and large canvas tent). If money weren't tight, I'd like to replace with either a turbo engine, or put a more modern Ford engine in (if this is possible), but will have to keep it as is for now.

[rover]

It will be the belt, you will have to remove the head and sump if you cant find the collets, once the head is off try to turn the engine by hand, if all is free then carry on, it wont cost a lot

Rover.

[Big_Andy]

Thanks, Rover, that's what I'm hoping for.

[Frag]

Why would it drop the valve/loose collets in the first place ?,not something i`ve seen much on the di.....

Although the valve stem will lift back up,how do you know the valve itself is still on the other end

Suppose it will come clear when you lift the head.

[rover]

I've not seen it MUCH either, but I have seen it.... on occasion when the belt has slipped, the compression being high enough to keep the valve in place as the rocker comes down on the valve and dislodging the collets. Only a head off will tell though eh..

Rover.

[Big_Andy]

And here is the glorious sight I found on getting the head off, post CHristmas.


The damage to the head - missing valve and damaged valve


The valve jammed into the piston crown

[AlanN]

Holy *rap

[alanwh]

Bloody hell, you don't see that every day

[Retrohowla]

Gotta hand it to you, thats a dam fine mess that is