Hi all, before I start i want to thank everyone who's provided useful advice on this forum, i've not posted properly yet but never needed to until now thanks to all the great info on here.
So this little story is about my treasured 2003 156 1.9 JTD (8v version) that i bought about a year ago, and starts only3 months ago with a problem as simple as my auxiliary belt coming off. My mechanic reckoned there was a little play in one of the tensioners but said it would be expensive to replace so I may as well just have the belt done and see how long it lasted. I also had the service, cam belt change and MoT done about the same time, maybe a couple of weeks after. Then a month ago the auxiliary belt went again, so he put another one on. The belt was shredding on the outside a little and coming off, rather than snapping which I thought odd but again just put it down to the tensioner.
Then last week (Saturday to be precise) the belt came off yet again. A bit annoying that my mechanic was on holiday at the time so had to take it down to my local Kwik-Fit instead (if anyoneís thinking of taking a car to Kwik-fit with engine problems, just donít!). They slapped the belt on, I paid my £60 and on my way I went.
I was back in the garage within ten minutes, another belt down. They had another look the next day and put it down to the crank pulley and tensioner vibrating. £200 later and both those on, car ready at 5:45pm, it was back in their car park again by 6pm after the latest belt came off.
The following day just before lunch I get a call from their managerÖ ďYeah our expert mechanic has had a look and the cam belt has gone while heís testing itĒ.
So itís gone from a fan belt issue to something more serious, but keep that in mind for later onÖ
Now having recovered her sheís back in my driveway and I had a spare few hours to kill this afternoon so thought Iíd have a butcherís under the bonnet to see whatís going on. As soon as I got the engine cover off I noticed a bit of an issueÖ see if you can see it:
No? look a bit closer:
Just there, you can see the cam belt itself peeking through, and having torn a hole through, the top cam belt cover. Removing that I get to see this:
Yup, thatís the cam pulley bolt sheared off. The cam beltís alright though! So having rescued that and removing what was left of the bolt from the camshaft, the pulley and the belt pushed out of the way, I get the cam cover off and cam bearings out of the way and this is what I see:
Thereís two things I noticed wrong here, firstly in the space directly below valve 4 in the picture (itís a very dark area) is the shim bucket head (I think thatís what itís called, the thing about the size of a thick 10p piece that sits on the shims) from valve 3 (1 being the leftmost on the picture) and itís broken, snapped on the top side. Secondly, thereís the little problem of this at the end of the camshaft:
Yup, thatís broken too. I managed to get the camshaft off and the broken bit, and thatís left me with this (valves 3 & 4 shown):
So the shim bucket at 3 clearly needs replacing as itís cracked to hell. One important thing to note is that no matter what Iíve tried, the shim bucket wonít come out, all the others have come out alright and none are cracked, including 4. However, I canít get 4 back in now!!
This leaves me with a number of questions:
1) Do I have to take the head off to access the valves as I need to find out what the damage is to them? Will there be any damage to the pistons?
2) Will I be able to get the jammed shim bucket out of the head to replace that? As all the others seem to move freely Iím assuming I donít need to do anything with them?
3) Should the shim bucket glide back in easily once removed?
4) Given the camshaft cracked at the vacuum pump end, can I assume thatís because of the vacuum pump itself and I need a new one?
5) Would the cracked camshaft have caused the bolt to shear off and in turn cause the pulley come off? The notch on the pulley also sheared off as well so I need to replace the pulley itself too.
6) What parts would I need to replace? At the moment Iím up to: 2 shim buckets, 2 shim bucket heads, camshaft and pulley, vacuum pump, cam belt and tensioner, valves.
7) Final and probably most important question, could any problems up top have caused the auxiliary belt issues Iíve been experiencing? Iím assuming the vacuum pump has been dodgy for a while, could excessive strain on the cam have caused the frequent auxiliary belt slipping in some way? I need to work out if itís really going to be worth fixing given Iíve spent £1100 on repairs since last November.
Unless anyone says anything to the contrary Iím going to have a go at taking the head off tomorrow. Wohoo!! Thatís the end, thanks for listening and any help will be much appreciated!