Hi All,

Im new here, so thank you in advance for your answers!!

I bought a Ford Fiesta MK5 van y. 2004, 1.4 TDCI a few weeks back. The previous owner stated that the car run just fine but wont start after it run out of fuel.

In an attempt to start the engine they removed the fuel pump from the tank and broke one connection, so we guessed that only the pump had to replaced.

As it turned out it was a complete timing belt failure, we could start the engine at all, it turned over, but did not ignite.

Upon removing the valve head cover we found one broken rocker arm and one broken rocker/tappet, replaced both, and one intake valve, beneath the broken rocker arm, we checked all the arms and valves for any damages oc, replaced the head gasket, all of the rockers and sealants, checked alos the camshaft. The camshaft gear seems to be from a different car, so we had to figure out how to adjust it manually so we could turn over the engine by hand. We changed the whole timing belt along with the tensioner and water pump, managed to turn over the engine and put back together the whole engine.

The car wont start, the starter turns the engine over, but there is a strange chugging noise coming from the engine, something is clearly wrong.

The car run before the timing belt issue just fine, so the injectors and all the other stuff should be okay.

Any help would be much appreciated, we have been struggling with the car for almost two weeks now.

BR

Thomas

Sounds like it didn't run out of fuel...unless the cambelt snapped at exactly the same time.  

There's no pump in the tank pickup.  You have to manually prime the fuel system on these, there should be a primer bulb on the left hand side of the engine as you look at it.  It won't start until you've primed the system.  There may be other faults as well though.

Thx for the reply, Ive done that a couple of times, there should be no air left in the fuel line....I think the main issue here is that messy gear head (from another car) on the camshaft, sadly it is very diffucult to find one online...

I hope that the pistons and the crankshaft are fine, dont want to take apart the whole engine.

3 hours ago, Dr_Z3RO said:

Thx for the reply, Ive done that a couple of times, there should be no air left in the fuel line....I think the main issue here is that messy gear head (from another car) on the camshaft, sadly it is very diffucult to find one online...

I hope that the pistons and the crankshaft are fine, dont want to take apart the whole engine.

I'm not really sure what you mean, why would the cam sprocket be changed for one from another car?  If there are any breakers yards near you, they'll probably have plenty of 1.4 TDCi engines that they could split the sprocket from, though it's not something you'd usually advertise separately online.

 

I dont know either, but I found a few used ones on ebay (sprockets), and they look differently, the mechanic who worked on the car lately said the same, he thinks someone just changed it. The weird engine noise when cranking up the car makes me worry the most...

So, the whole camshaft was faulty, after replacing the shaft the engine was running fine....now the clutch is making some problems, the story continues!