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Vauxhall Astra 1.9 Z19DTH 2008 - Smokes badly after timing belt failure - Fixed #

Posted by Kenny Mcfadyen on June 7, 2013, 8:44 pm

Year of Manufacture *: 2008
Engine Size and Code *: 1.9 diesel Z19DTH
( Optional) Fault Codes: No fault codes

Hi all
Been a member for just a couple of month and this will be my 1st post.
Car was towed in by the AA with timing belt failure.
Stripped it down to find all exhaust valves bent and all exhaust rockers broken. So we fitted 16 new valves and 8 new rockers.
Built car back up having fitted new
Timing belt kit
Water pump
Head gasket
Head bolts
Gaskets
16 valves
8 rockers
On starting car after job completed car smokes badly and does not run properly. Smoke is black from incomplete combustion.
Our first thought was timing was a tooth out.
So wee stripped down to find timing is perfect ( we used vauxhall timing tools and clock dial gauge)
The car has no fault codes
Things we have tried
Swapping with a good running donor car.
4 injectors
Air flow sensor
Air pressure sensor in manifold
Egr valve
Compressions are all even at 30 bar
Disconnect exhaust
Turbo pressure is good
All reading in live data are good.
Called in our auto spark who has tech
2 and still no fault codes in Ecu. He also can't find problem.
Advised wrongly by main dealer master tech who thought that cam lobs on camshafts might have moved.
Camshafts are perfect and camshaft and lobs are the same piece of metal.
Reading live data from our donor car
The only difference is
Injection quantity is 4 mm
And our problem car reading is 16mm cubed.
Bosch say it should be between 5 and 8 at idle.
We don't know if our reading is higher because the car is not running properly or could this be our problem.
Hoping someone out there could help
Thanks

Re: Vauxhall Astra. Badly smokes after timing belt failure

Posted by Ian Slattery <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT1196' width='330' height='300' border=0 style='border:none;'> on June 7, 2013, 9:43 pm, in reply to "Vauxhall Astra. Badly smokes after timing belt failure"

Hi Kenny.

Have you checked the keyway on the crank. I know you have checked it with a dial gauge but it may be worth a look.

If you can scope the crank v cam, it normally flags po340 but here a link. hth.

do a search on p0340

Fixed # - James Eardley November 23, 2012, 10:51 pm

Vauxhall Zafira 1.9 CDTi Z19 DT 2008 - Hard starting cold or warm, code P0340 - Fixed #

Regards Ian.

Re: Vauxhall Astra. Badly smokes after timing belt failure

Posted by Kenny <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3566' width='330' height='300' border=0 style='border:none;'> on June 7, 2013, 10:00 pm, in reply to "Re: Vauxhall Astra. Badly smokes after timing belt failure"
Kenny McFadyen

Sorry Ian
I ment to say that in my post crank and cam sprockets key ways are both fine.
Thanks

Re: Vauxhall Astra. Badly smokes after timing belt failure

Posted by george ambelas <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3245' width='330' height='300' border=0 style='border:none;'> on June 7, 2013, 10:46 pm, in reply to "Vauxhall Astra. Badly smokes after timing belt failure"
George Ambelas

does the injection quantity remain high when it warms up? did you scope the cts?

Re: Vauxhall Astra. Badly smokes after timing belt failure

Posted by Kenny Mcfadyen on June 7, 2013, 11:25 pm, in reply to "Re: Vauxhall Astra. Badly smokes after timing belt failure"
Edited by board administrator June 10, 2013, 1:29 pm

Hi George
It remains the same yes and not got a scope

Re: Vauxhall Astra. Badly smokes after timing belt failure

Posted by aidan birley <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT2879' width='330' height='300' border=0 style='border:none;'> on June 8, 2013, 7:33 am, in reply to "Re: Vauxhall Astra. Badly smokes after timing belt failure"
Aidan Birley

Hi

Bit of a long shot, but any chance the injector washers are incorrect thickness ?

Thickness of the sealing washer is surprisingly critical to correct combustion.

Aidan

Re: Vauxhall Astra. Badly smokes after timing belt failure

Posted by Bryan Smith <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5330' width='330' height='300' border=0 style='border:none;'> on June 8, 2013, 9:12 am, in reply to "Vauxhall Astra. Badly smokes after timing belt failure"

I think you will find that the camshafts are in two parts which are only pressed together. My bet is that they have moved. I know of someone that just twisted one back again and it ran fine afterwards. It was an older engine code on an Astra G but I suspect it will be the same.
HTH's
Bryan.
Just re-read your post and see that you have checked this although you seem to say that the lobes are part of the cam. They are, but the cam is in two half's so it may be worth another look.

Re: Vauxhall Astra. Badly smokes after timing belt failure

Posted by Kenny Mcfadyen on June 8, 2013, 9:48 am, in reply to "Re: Vauxhall Astra. Badly smokes after timing belt failure"
Edited by board administrator June 10, 2013, 1:29 pm

Thanks Bryan
We checked and double checked the camshafts
And we where convinced that it is a one piece. They also
Look in perfect condition.
Are you saying that it joins in the middle. We will
Have another close look at them.
Thanks again

Re: Vauxhall Astra. Badly smokes after timing belt failure

Posted by Mark Carter <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT1428' width='330' height='300' border=0 style='border:none;'> on June 8, 2013, 11:18 am, in reply to "Re: Vauxhall Astra. Badly smokes after timing belt failure"
Mark Carter

>>> we where convinced that it is a one piece. They also Look in perfect condition. <<<

You will not see any damage to the camshafts, if they are the type people are saying they will be hollow.

The lobes are located on the hollow tube in production and the tube is expanded hydraulically to hold the lobes is place.

16mm injection quantity is excessive (bear in mind that it is a calculated value and not measured directly)and could be caused by incorrect valve timing (as well as other issues)

Mark

Modern cars, Its all wizardry and witchcraft

Re: Vauxhall Astra. Badly smokes after timing belt failure

Posted by Kenny Mcfadyen on June 8, 2013, 7:05 pm, in reply to "Re: Vauxhall Astra. Badly smokes after timing belt failure"
Edited by board administrator June 10, 2013, 1:30 pm

Thanks Mark
Thanks for your post
Just got a cut down to 8 at golf today 😄😄
Will be looking again at this nightmare car on
Monday 😡
Will post my findings, but think it might be the cams at
Fault.
Thanks to all you guys who took the time to reply to
Our problem.
Cheers

Re: Vauxhall Astra. Badly smokes after timing belt failure

Posted by Phil Madeira <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat1479' width='330' height='300' border=0 style='border:none;'> on June 8, 2013, 10:01 pm, in reply to "Vauxhall Astra. Badly smokes after timing belt failure"

Re: Vauxhall Astra. Badly smokes after timing belt failure

Posted by andyhyoung <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5148' width='330' height='300' border=0 style='border:none;'> on June 8, 2013, 10:55 pm, in reply to "Re: Vauxhall Astra. Badly smokes after timing belt failure"
Andrew Young

May be off track here,but have you checked the cam to cam timing and the relative positions of the sprockets to the camshafts.There are no keyways on the cam drive sprockets;they may have spun.

Re: Vauxhall Astra. Badly smokes after timing belt failure

Posted by Steve Shaw <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT1301' width='330' height='300' border=0 style='border:none;'> on June 10, 2013, 11:39 pm, in reply to "Re: Vauxhall Astra. Badly smokes after timing belt failure"
Steve Shaw

hi kenny
we've had a zafira where the cams had moved at the mesh gear end as posted above, my local dealer said they only put a locking tool in the front cam & had never heard of it happening, hmm! well anyway it does & unless you're very careful they can move as you re-tighten the gear & damage the locking tool to boot.

hth

Steve

Re: Vauxhall Astra. Badly smokes after timing belt failure

Posted by Bryan Smith <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5330' width='330' height='300' border=0 style='border:none;'> on June 11, 2013, 8:02 am, in reply to "Re: Vauxhall Astra. Badly smokes after timing belt failure"
Bryan Smith

I may be wrong on how many parts there are to each cam but I know it is very difficult to see when they have moved. I would think the only way to check them in situ is to check how many degrees the crank is turned for each valve opening.
Bryan.

Re: Vauxhall Astra. Badly smokes after timing belt failure

Posted by Kenny Mcfadyen on June 11, 2013, 6:33 pm, in reply to "Re: Vauxhall Astra. Badly smokes after timing belt failure"
Edited by board administrator June 12, 2013, 7:37 am

FIXED
Thanks guys for taking time out your day and emailing responses about our problem.
Our camshafts where fine.
It turns out our problem was injector washers where to thick. (Thanks to Aiden Birley for his post)
The 1st set of washers we used where just under 1mm thicker.
After reading Aiden post again we ordered 4 new washers from the dealer.
We where amazed that this was our problem.
Stupid us
We live and learn.
Thanks again for all your posts

Re: Vauxhall Astra. Badly smokes after timing belt failure

Posted by Steve Shaw <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT1301' width='330' height='300' border=0 style='border:none;'> on June 11, 2013, 10:36 pm, in reply to "Re: Vauxhall Astra. Badly smokes after timing belt failure"
Steve Shaw

Bryan
in my sealey timing kit i have 2 spring loaded cam timing pins so it's quite straightforward to check, but the induction manifold obstructs access if fitted to the head.

Steve

Fixed #

Posted by Kenny Mcfadyen on June 12, 2013, 7:34 am, in reply to "Re: Vauxhall Astra. Badly smokes after timing belt failure"
Edited by board administrator June 12, 2013, 7:37 am

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