Ford Mondeo 2.0TDCI 2005 - timing chain broke. Changed the timing chain, new head. The problem is that the car doesn't run at all. Shakes like hell, no response from the gas pedal. The car hasn't left the garage in a year because no one has figured this out. Before the chain broke, the car was in top notch condition.

At first it didn't start at all. By using brake cleaner the car started, but runned very rough and died after a few moments. The exhaust got so hot it melted the tip of the exhaust fume extractor. After the ECU was updated, the car would start better and run longer(about 30 seconds and then just dies). 

 

Symptoms - rough running and shaking at idle, dies after about 30 seconds, when the engine responds to the accelerator, won't go above 1500RPM(turbo spools like crazy at this RPM, stututu noises after letting go of the gas).

No fault codes, all live data seems okay. Checked by several people and different diagnostic softwares. Only thing is that the injectors try to spray so much fuel. I think it was 30mg/str by live data. 

 

What has been done: 

- New timing chain kit, new head(kept old camshafts).

- Updated ECU software

- New injectors

- New Fuel rail pressure sensor(threw a code at some point)

- New camshaft and crank. pos sensor

- Cylinder compressions measured, they are OKAY.

- Timing checked again, OK.

- Intake and exhaust manifolds removed, no effect. 

- EGR bypassed, no effect.

- Unplugging MAF sensor, no effect.

- Tried new fuel, no effect even after running straight from the canister.

- Tried adjusting cam timing via cam gears, no effect.

- Compared the camshafts on the car to known good camshafts, no difference. 

- Using the oscilloscope, measured the injection time in relation to crankshaft position signal and then compared them with a working car's signals. Seems like the injection is opened too early, and the fuel starts to burn too early. why??

 

Almost everything has been checked and all the tricks have been tried but the car is still not running. If anyone has got any ideas, please let me know.

what condition were the pistons in after the timing chain broke ? Did they not hit the inlet/exhaust valves ?

Possibly poorly bled fuel system

Triple/quadruple check the timing

Loose/damaged connection?

I think I'd be looking at the bottom end too.

Possibly the injectors could be wrong - do new injectors not need calibrating?

Injectors coded, even tried the injectors from a working car. Fuel system is bled. All the wiring checked.

The intake valves were hit, rocker arms broken. Pistons, rods were replaced. The engine was fully tore down. 

Timing and compression has been checked very many times, it is okay.

On 12/10/2021 at 2:21 PM, asd123asd said:

Injectors coded, even tried the injectors from a working car. Fuel system is bled. All the wiring checked.

The intake valves were hit, rocker arms broken. Pistons, rods were replaced. The engine was fully tore down. 

Timing and compression has been checked very many times, it is okay.

It would have been much easier and a lot cheaper just have replaced the engine. It is very rare that its a good idea to try an repair and engine after major damage caused by a timing chain failure.

Don't shoot me for being daft, but, has the flywheel gone down?

Is the crank bent?