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?

 

[NdL]

Today I made some investigation.
I removed the cam shaft.

Started of by putting engine timing correctly.
I then removed the timing belt.
Because the cam is scrap I just used a big gripper to hold the cam so I could remove the cam gear sprocket.

I’ll have to order the correct tool to hold the cam in place later on.
But I saw another member on the forum that bought a locking tool and had problems with the alignment. Is there different tools?

After the cam sprocket, I removed the vacuum pump, and the end piece. Don’t know the exact word for it.
But it holds the camshaft.
That piece is in aluminium, and were pretty damaged - see attached pictures
Is there any part number for this?
Would be nice to have another one fitted.

The camshaft as mentioned before had no lobe on exhaust cylinder 1.
Except that no other worrying wear.

After I removed the camshaft I tried to press the valves down. Every valve felt normal except for No1 exhaust. I could only push it a few millimeters.

Before I remove the whole engine head.
Is it an explainable reason to why I couldn’t push it down further?

 

[NdL]

And now I also got stuck on the OE-number of the camshaft.
Is there a good way to be sure you get the right number?

If i get everything right, the number should be - 46552986
Anyone who can confirm?
Engine code - 230A3.000
Year - 1998
Motor - 1,9TD

 

[bugsymike]

Ouch!!! That looks like quite serious damage. I suspect the exhaust valve is bent and jammed in the valve guide in cylinder head, possibly meaning it will have impacted with the piston causing further damage.
More will be seen with cylinder head removed.
Incidentally the damage in the aluminium housing also looks like a crack there. Many parts where cam mounts in cylinder head ar "line bored" which may mean come with the cylinder head complete, if available!
It is possible some metal from the damged engine got into the oil and has gone around the rest of the system possibly causing more damage that is not visible at present.

 

[NdL]

Today I removed the cylinder head.
Everything looked surprisingly well.
No damage to the pistons, and all cylinder walls felt good.

I”ll change the valve+guide.
And will grind all valve seats.

Just need to find the correct camshaft.