200tdi cut out and will not restart

dag019 said:

And the winner is......

Timing belt.
Very annoying. It was on my list to do as the interval is up in 8k so it has gone early!

Other than everything needed to do the belt and a new set of push rods what else do I need to do?
Do I need to take the head off to check the intervals will a set of push rods be all that is needed?

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check the cam followers using torch and looking down push rod hole if the socket is distorted head needs to come off to replace them ,if ok just replace bent rods adjust and watch each valve open fully and shut smoothly if they do guides and valve stems are very likely ok

jamesmartin said:

check the cam followers using torch and looking down push rod hole if the socket is distorted head needs to come off to replace them ,if ok just replace bent rods adjust and watch each valve open fully and shut smoothly if they do guides and valve stems are very likely ok

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Many thanks, will order a set of rods, and timing belt kit. Is a push rod a push rod or like all things are some better than others?

dag019 said:

It is the belt. That was my first thought as well. I was just being hopeful it would be something else.
It Was changed about 65k ago so was on y list to do again in rhe near future as I knew it was coming up to being due.

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Belt may be due at 70 (or 75K miles), but it is also lifed at 5 years irrespective of mileage. Just done mine a couple of months ago, only had about 35K on it but didn't want to risk it even though it looked fine. Doesn't help if belt gets contaminated with oil either. Anyway good luck and hopefully minimal collateral damage

dag019 said:

Many thanks, will order a set of rods, and timing belt kit. Is a push rod a push rod or like all things are some better than others?

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your not going to find any from the original british factory as its long gone but an oem would be best bet turners do an oem for about 3 quid

Kwakerman said:

Belt may be due at 70 (or 75K miles), but it is also lifed at 5 years irrespective of mileage. Just done mine a couple of months ago, only had about 35K on it but didn't want to risk it even though it looked fine. Doesn't help if belt gets contaminated with oil either. Anyway good luck and hopefully minimal collateral damage

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It was last replaced about three an half years ago so not due on time but was coming up on 70k so getting due on distance. I do fairly high mileage in mine.

ERR388 - water pump gasket
ERR1195 - timing cover gasket
ETC8560 - idler
ERR2530 - tensioner
ETC8550 - timing belt
ERR6490 - front crank seal
ETC4154 - timing cover crank seal

546799 - push rod (link)

Does the above list look like everything I will need to do the timing belt and push rods or have a missed something out/got the incorrect part numbers?

Everything will be OEM parts and looks to all be stocked at paddocks which is a bonus. I will order this to start with so I can get on with replacing the timing belt. AS i disassemble things I will check the cam followers as mentioned by @jamesmartin and if I find they need replacing will then do another order to include everything necessary to strip the head off.

jamesmartin said:

your not going to find any from the original british factory as its long gone but an oem would be best bet turners do an oem for about 3 quid

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Do the push rods need to be replaced as a complete set of 8 or do I just replace the ones which are bent?

dag019 said:

Do the push rods need to be replaced as a complete set of 8 or do I just replace the ones which are bent?

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just ones that are bent or showing wear on the ball end

dag019 said:

Do the push rods need to be replaced as a complete set of 8 or do I just replace the ones which are bent?

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I would suggest that even ones that look straight are rolled on a flat surface to check they are truly straight

Kwakerman said:

I would suggest that even ones that look straight are rolled on a flat surface to check they are truly straight

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as the full set of 8 is only £18 for OEM I think I will just order the full set, and swap them all over.

Rocker cover seals?
Before ordering parts I would look down the push rod tunnels and make sure the the rollers and followers are not damaged.
Head off to fix so you'll need those gaskets as well.

Just so everything is in one place I will update this with my progress and another problem!

Found the initial problem:



The belt look like it has worn the edge down is is very thin, what causes this?

And then the secondary problem:



Push rods have now been replaced, thankfully on inspection the cam followers looked to be fine.

I do however have a new problem!
The stud for the idler pulley (disco 200tdi) look slike it has been previously stripped and repaired with a helicoil. I fear this has now stripped as well as when undoing the nut for the idler the stud came out with what I am amusing is a helicoil, and some aluminum threads lodge in it! That was the final starw for this eveing so I have given up and come inside to warm up. From the pictures below can anyone confirm this is a helicoil repair? If so what is the next step to repair again, I am assuming you cannot fit multiple helicoils.

dag019 said:

Just so everything is in one place I will update this with my progress and another problem!

Found the initial problem:

View attachment 163167 View attachment 163168

The belt look like it has worn the edge down is is very thin, what causes this?

And then the secondary problem:

View attachment 163170 View attachment 163171 View attachment 163169

Push rods have now been replaced, thankfully on inspection the cam followers looked to be fine.

I do however have a new problem!
The stud for the idler pulley (disco 200tdi) look slike it has been previously stripped and repaired with a helicoil. I fear this has now stripped as well as when undoing the nut for the idler the stud came out with what I am amusing is a helicoil, and some aluminum threads lodge in it! That was the final starw for this eveing so I have given up and come inside to warm up. From the pictures below can anyone confirm this is a helicoil repair? If so what is the next step to repair again, I am assuming you cannot fit multiple helicoils.
View attachment 163173 View attachment 163172

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Belt wearing on the sides is usually caused by pulleys out of alignment. Or one or more of the pulleys not being straight on it's shaft.

Turboman said:

Belt wearing on the sides is usually caused by pulleys out of alignment. Or one or more of the pulleys not being straight on it's shaft.

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And how do you go about testing that and rectifying the issue?

DTI

dag019 said:

And how do you go about testing that and rectifying the issue?

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Visual check of run out, or use a dial gauge on the pulley rims.

Ok will have a look at that. If one of them is out is the only option replacement? Guessing the problem will lie with a pulley not the crank or cam shaft?

Any suggestions on how to refit the idler stud?

dag019 said:

Ok will have a look at that. If one of them is out is the only option replacement? Guessing the problem will lie with a pulley not the crank or cam shaft?

Any suggestions on how to refit the idler stud?

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No particular reason the end of the crank or camshaft couldn't be bent, such things are not unknown.

My experience of helicoils is quite limited, and a long time ago, I will leave that one for James.

dag019 said:

Ok will have a look at that. If one of them is out is the only option replacement? Guessing the problem will lie with a pulley not the crank or cam shaft?

Any suggestions on how to refit the idler stud?

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You might find that the pulley on the injector pump shaft is incorrectly fitted, or the pump is not firmly bolted to the timing case. I have seen both of those before.

Turboman said:

You might find that the pulley on the injector pump shaft is incorrectly fitted, or the pump is not firmly bolted to the timing case. I have seen both of those before.

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Many thanks I will check that tomorrow.