Decided to have a go at replacing the worn and leaky oil seals on my 55d van and change the timing belts and tensioners etc while I had it apart. Got the father in law to give me a hand cos I'd never done this sort of job before. Turns out he'd never done it on a diesel engine and he realised how comlicated it is to sort out when you bugger it up and lose all the timing lol.
I had bought some timing pins for it and suggested using them to lock everything in place before we started taking bits off but he must have thought we didnt need to, I left the decisions to him seeing as he was more knowledgeable with engines. Anyway, we took all the belts and pulleys off and then realised there were no timing marks behind the pulleys so had to re time the whole lot when it came to refitting everything
The father in law has one of those torque wrenches from years ago with a big pointing bar on it that points to the amount of torque applied lmao, I did think it was a bit dodgy, and then after we torqued the cap nuts up to 20 ft/lbs we turned the engine over a couple of times via the crank pully and then turned the key, it wouldnt fire up and then there was a fairly noisy "PING"!!, and that was the sound of my cam shaft snapping
I reckon its where we'd over tightened the cap nuts with his dodgy wrench lol. So I got another one from the scrappy plus all the shells and nuts etc for it and put these in my engine and torqued them all up with a real wrench (brand new one ;P)
next mission was the fuel injection pump, we knew it wasn't timed right as it didnt fire up at all or even attempt to when we turned the key.
We must have got the timing wrong about 5 times before a mate of mine popped over and realised we hadn't losened the vernier pulley off on the injection pump. We had a Haynes manual for my van and it didnt say anything about fiddling about with the vernier, these modern Haynes man's are crap imo, the old ones were much better I'm sure!
What a pain in the arse this job has been, its taken days to sort out, but finally its running now, I drove her home last night, the engine sounds sweet but there are still two problems left and if anyone can suggest anything to sort them out it would be great.
[i][i]1: where we tried to undo the little 8 or 10 mm bolt that holds the timing belt cover in place to the left of the cam pulley it sheared off so now the metal plate that sits behind the pulley and timing cover rubs on the cam pulley causing a lot of heat and I'm worried it may cause the timing belt to snap at some point!!
2: where the old cam shaft snapped, it bent two of the three female thread shafts that the rocker cover sits on, not much but enough to make two of them a bit hard to wind the bolts into and one of them has cross threaded, I hoped it would be alright for a while but when I got home last night I checked and there was oil all over the rocker cover on the opposite end to the timing belts etc, where its obviously not tight enough to get a good seal and where the bolt is missing from the top.[/i][/i]