Technical 1,9TD Camshaft problems

[NdL]

Hi.
Last week I started to notice lack of power in my 1,9TD 1998. - 230A3.000
Started to black smoke a lot.

I then checked all turbo hoses, and found that a clamp was broken closest to the turbo.
Changed it, and felt like the motor ran well again.

I then drove for 100km. And I felt lack of power again.
After some km, the motor started to sound really bad.
Hard knocking sound. And when given gas i hear a mechanic rattle.
But it starts with ease, and have a good idle. But it sounds really bad.

Yestorday i started my investigation about the problem.
I removed the turbo and checked it. No problems with it.

I then removed the engine top cover and noticed one of the lobes where completely round. There was no lobe at all. (the one furthest to the left seen from front)

What can have caused this?
What actions do I need to do now?

A new camshaft should be no problem. But I don't know if I have to remove the whole engine head.
I would also need information about the timing belt settings.
Don't find anything for this motor in the manuals I have.

Thanks.

 

[Communicator]

Hi.
Last week I started to notice lack of power in my 1,9TD 1998. - 230A3.000
Started to black smoke a lot.

I then checked all turbo hoses, and found that a clamp was broken closest to the turbo.
Changed it, and felt like the motor ran well again.

I then drove for 100km. And I felt lack of power again.
After some km, the motor started to sound really bad.
Hard knocking sound. And when given gas i hear a mechanic rattle.
But it starts with ease, and have a good idle. But it sounds really bad.

Yestorday i started my investigation about the problem.
I removed the turbo and checked it. No problems with it.

I then removed the engine top cover and noticed one of the lobes where completely round. There was no lobe at all. (the one furthest to the left seen from front)

What can have caused this?
What actions do I need to do now?

A new camshaft should be no problem. But I don't know if I have to remove the whole engine head.
I would also need information about the timing belt settings.
Don't find anything for this motor in the manuals I have.

Thanks.

@bugsymike

 

[NdL]

I attached two videos.
The first on is from four days ago. The engine sounded normal. Only problem was heavy black smoke

The second video is how the engine sounds and runs now.

 

[bugsymike]

I attached two videos.
The first on is from four days ago. The engine sounded normal. Only problem was heavy black smoke

The second video is how the engine sounds and runs now.

Certainly doesn't sound to good, even previous video fair amount of smoke which may be related to not enough turbo boost due to air leak etc.?
Knock is worrying, you may end up stripping further than camshaft and followers/rockers. The rounded cam lobe I assume is over a valve, I know this may sound stupid but some have a seperate lobe for a fuel pump/brake vacuum etc.
It is not an engine I have had much to do with.
I have these details in photos below, note there are two choices re cam belt timing details depending on adjustable pulley etc, so read carefully to confirm what you have.
On the Technical Data Manual, the point of the scissors should correspond with your model, but check.

 

[NdL]

Thanks for answer.
Yes. Something was obviously wrong before as well. I thought of bad injectors, so I even ordered a 27mm open socket to remove them and take them for cleaning and inspection.
And that’s why I also removed the turbo, because it did not felt right with the smoke.

Probably it is the rod for exhaust on cylinder 1 that doesn’t open.(where the lobe is gone)
I can feel air coming the wrong way in the intake.

Thanks for your pictures.
But I don’t really understand the page with torques. Is the 20/30nm-180-90degree. Is that for the head bolts?


And do you really need the special tool for the tensioner for the cam belt? Is there any other good way to know you have the right tension?

 

[bugsymike]

Thanks for answer.
Yes. Something was obviously wrong before as well. I thought of bad injectors, so I even ordered a 27mm open socket to remove them and take them for cleaning and inspection.
And that’s why I also removed the turbo, because it did not felt right with the smoke.

Probably it is the rod for exhaust on cylinder 1 that doesn’t open.(where the lobe is gone)
I can feel air coming the wrong way in the intake.

Thanks for your pictures.
But I don’t really understand the page with torques. Is the 20/30nm-180-90degree. Is that for the head bolts?


And do you really need the special tool for the tensioner for the cam belt? Is there any other good way to know you have the right tension?

Obviously check with another data source , but I beleieve it means as the instructions on the right hand pull out page column that you tighten to 20nm, let it settle then 30nm, then 180degrees, then a further 90degrees.
It is not something I feel happy when doing as you always feel the bolts are going to snap. So it is important to use new bolts of a good quality, clean threads in cylinder block thoroughly and if new bolts come with a special thread lubricant use it as advised.
Re the tensioning tool, I have never used one, just used personal experience, so maybe check what old one feels like in place before dismantling, then turn the adjuster ( I use a bent nose pair of pliers in the two holes) then pulley bearing against the belt tighten so the belt may be slightly twisted at it's longest run.) I turn the engine over by hand several times to settle the belt then recheck the tension and again after running the engine.
Note if too tight it will make guide bearings noisy and cause premature failure!!!
Re the cam lobe side it is quite possible the valve has been damaged and have buried it's self in the cylinder head and piston, which on some engines (2.5-2.8 Sofim Ducato) bends the conrods so a major rebuild.
My advise is strip and carefully examine all relevant parts before ordering new parts.
Is it possible a part of the injector nozzle came loose and caused the issue?